CRL-1 / CRL-2 CABLE FESTOON SYSTEM - STEMMANN · CRL-1 / CRL-2 CABLE FESTOON SYSTEM Set up of a...

STEMMANN-TECHNIK GmbH ▪ Niedersachsenstr. 2 ▪ 48465 Schüttorf ▪ Germany

CRL-1 / CRL-2 CABLE FESTOON SYSTEMSet up of a C-Rail System

Based on the di�erent cable trolley versions and numerous components you can compile your individual C-rail system. In addition to straight travelling direction we manufacure curved sections for special requirements with a minimal radius of 1000 mm.Depending on the application, the installati-on is carried out as ceiling or wall assembly to create a rigid system.

TECHNICAL TERMS

Staking lengthThe staking length is the total length of all cable trolleys in a pushed together state.

Travelling distanceThe travelling distance is the total length of thecable trolley system (without staking length).

SagThe sag defines the distance between the bottom edge ofthe C-rail and the lowest point of the cable or hose.The maximum sag is achieved as soon as the cabletrolleys are pushed together.

Cable festoon systemThe whole system ist re�ered as the cable festoon system, includingthe cable trolleys, C-rails und all other components.

REQUIRED COMPONENTS

For the optimal combination of a cable festoon system you will need the following components in accordingdesign and amount:

■ Cables / hoses■ C-rail Depending on the application area CRL-1 or CRL-2 Rails are used.

■ Cable trolley The cable trolley type is selected according to the C-rail and depends on the cable or hose package, the travelling speed, the weight load and the environmental influences.

■ End support One end support is required for each cable festoon system.

■ Towing attachment One towing attachement is required for each cable festoon system.

■ C-Rail hangers Hangers for wall or ceiling mounting are required in a corresponding quantity depending on the system length, the suspension distance and the C-rail profile.

■ C-Rail joints The required amount of joints depends on the system length and the C-rail profile.

■ Rail stopper For every cable festoon system one rail stopper is required.

■ Endcap For every cable festoon system two endcaps are required.

Additional components:■ Towing trolley■ Driving trolley for the final connection unit

■ Wall traverses■ Clamps/traverses for I-beam assembly

CRL-1 CABLE TROLLEY / END SUPPORTfor Flat Cables, Rigid Plastic Design

Art.-Nr. 6600865 / ...867


This cable trolley is designed for the „CRL-1“ C-rail to transport flat cables with a maximum height up to 15 mm. We o�er this plastic cable trolley for maximum payload up to 8 kg.

CRL-1 cable trolley for flat cables, rigid plastic design and related end support

Trolley Support Clamping Material Rollers Pay- Travelling Rail Art.-No. End supportlength radius width / height load speed Art.-No.

85 mm 36 mm 55 mm 15 mm plastic plastic 8 kg 60 m/min CRL-1 6600865 6600867

55 55

Note: You´ll find the related towing attachement (Art-No. 6600866) at the according data sheet.

85

Ø24

27

R36R36

1515

19

78

CRL-1 CABLE TROLLEY / END SUPPORTfor Flat Cables, Swinging Design

Art.-Nr. 6610023 / ...24 / ...25


This cable trolley is designed for the „CRL-1“ C-rail to transport flat cables with a maximum height up to 15 mm.We o�er two di�erent types of cable trolleys, with either steel or plastic rollers, wich are suitable for di�erent payloads.


CRL-1 Cable trolley for flat cables, swinging design and related end support.

84

Ø 24

60

R25 R25

1515

52

81

60

52


84 mm 25 mm 50 mm 15 mm

steel

steel 15 kg 60 m/min CRL-1

6610024 6610025 (galvanised)

(galvanised)

8 kg 6610023

plastic

CRL-1 CABLE TROLLEY / END SUPPORTfor Flat Cables, Rigid Design

Art.-Nr. 6610026 / ...27 / ...30 / ...33 6610028 / ...31 / ...34


This cable trolley is designed for the „CRL-1“ C-rail to transport flat cables with a maximum height up to 25 mm. We o�er two di�erent types, either a steel version with plastic or steel rollers, or a plastic version.

CRL-1 Cable trolley for flat cables, rigid design and matching end support

R25 / R35 R25 / R35

80 / 125

36

50 / 80 50 / 80

15 / 2515 / 25

38



80 mm 25 mm

15 mm

plastic 8 kg 6610026 6610028

50 mm steel

steel 15 kg 60 m/min CRL-1

6610027

125 mm 35 mm

25 mm (galvanised)

(galvanised) 6610030 6610031

80 mm 6610033 6610034

Ø 24

80 / 125 1)

1

1 1) = The end supports Art.-Nr. 6610031 and 6610034 will be delieverd including a rail stopper.

CRL-1 CABLE TROLLEY / END SUPPORTfor Round Cables, Swinging Design

Art.-Nr. 6610039 / ...40 / ...45 ...46 / ...48 / ...49 ...41 / ...47 / ...50


This cable trolley is designed for the „CRL-1“ C-rail to transport up to three supports for round cables or hoses with max. 28 mm diameter. We o�er two di�erent types of cable trolleys, with either steel or plastic rollers, wich are suitable for di�erent payloads.

CRL-1 Cable trolley for round cables/hoses, swinging design and related end support.

84

52

50 / 130

47

52

50 / 130

40Ø24

80

Trolley Round Supports Material Rollers Pay Travelling Rail Art.-No. End supportlength cable amount /height load speed Art.-No.

max. 1x 1 piece steel (galvanised) 15 kg 6610040 6610041

10 - 28 mm 50 mm plastic 8 kg 6610039

84 mm max. 2 x 2 pieces

steel steel (galvanised) 15 kg

60 m/min

CRL-1 6610046

6610047 10 - 28 mm 100 mm (galvanised) plastic 8 kg 6610045

max. 3x 3 pieces steel (galvanised) 15 kg 6610049 6610050

10 - 28 mm 130 mm plastic 8 kg 6610048


CRL-2 CABLE TROLLEY / END SUPPORTfor Flat Cables, Swinging Design

Art.-Nr. 6610053 / ...54 / ...57 / ...58 6610061 / ...62 / ...65 / ...66


This cable trolley is designed for the „CRL-2“ C-rail to transport flat cables with a maximum height up to 30 mm. We o�er a steel version with two di�erent clamping widths and support radii suitable for payloads up to 15 kg.

Ø 8,5

CRL-2 Cable trolley for flat cables, swinging design and related end support

120

60 / 10060 / 100


Trolley Support Clamping Material Rollers Pay Travelling Rail Art.-No. End supportlength radius width / height load speed Art.-No.

25 mm

60 mm 30 mm

6610053 6610061

120 mm 100 mm

steel

steel 15 kg 60 m/min CRL-2 6610057 6610065

35 mm

60 mm 20 mm

(galvanised) (galvanised) 6610054 6610062

100 mm 6610058 6610066

Ø 33

20 / 30

4150

20 / 30

R25 / R35R25 / R35

200

CRL-2 CABLE TROLLEY / END SUPPORTfor Flat Cables, Rigid Design

Art.-Nr. 6610078 / ...79 / ...84 / ...86 ...80 / ...85 / ...87


This cable trolley is designed for the „CRL-2“ C-rail to transport flat cables with a maxim height up to 30 mm.We o�er a steel version with clamping widths from 60 mm to 150 mm, suitable for payloads up to 35 kg.

CRL-2 Cable trolley for flat cables, rigid design and related end support

150 / 120

60 / 1 00 / 150 60 / 100 / 150

200



150 mm 35 mm 60 mm

6610078 6610091

6610079 6610092

50 mm 100 mm 6610084 6610098

200 mm 150 mm 30 mm steel steel 35 kg 60 m/min CRL-2 6610086 6610099

60 mm (galvanised) (galvanised)

6610080 6610093

70 mm 100 mm 6610085 6610097

150 mm 6610087 6610100

R35 / R50 / R70 R35 / R50 / R70

Ø 33

30

46 50

30

CRL-2 END SUPPORT / TOWING ATTACHMENTfor CRL-2 Cable Trolley for Round Cables, Swinging Design

Art.-Nr. 6600846 / ...47


This towing attachment and the according end support are required for „CRL-2“ C-rail systems incl. cable trolley (Art. 6600845) for round cables. One end support and one towing attachment are necessary in each system.

Towing attachment for round cables, swinging design

Towing attachment Material Rollers Payload Travelling Rail Art.-No.length speed

100 mm steel (galvanised) steel (galvanised) 30 kg 60 m/min CRL-2 6600846

End support for round cables, swinging design

Material Art.-No.

steel (galvanised) 6600847

100

Ø45

54

Ø33

78

41

45

40

38 45,5

CRL-2 CABLE TROLLEYfor Round Cables, Swinging Design

Art.-Nr. 6600845


This cable trolley is designed for the „CRL-2“ C-rail system to transport supports for round cables and/or hoses up to 35 mm diameter and payloads up to 30 kg. Plan your customer-specific system by using the cable supports and the clamp connectors.

CRL-2 Cable trolley for round cables and hoses, swinging design

Trolley length Material Rollers Payload Travelling Rail Art.-No. speed

100 mm steel (galvanised) steel (galvanised) 30 kg 60 m/min CRL-2 6600845

CRL-2 Leitungsklemmen

Round cable Material Art.-No.

8 - 15 mm Ø 6600839

16 - 24 mm Ø aluminium 6600840

25 - 35 mm Ø 6600841

CRL-2 Cable clamp connector

for cable supports Art.-No.

8 - 15 Ø / 16 - 24 Ø / 25 - 35 Ø 55413

100

45,5

Ø33


The driving trolley is available for the „CRL-1“ as well as for the „CRL-2“ rail systems. It can be used to control crane systems for exemple. For accurate design we need relevant informa-tions on the used cables and cable trolleys, as well as the intended purpose.

DRIVING TROLLEYfor CRL-1 or CRL-2 Rail System

Art.-No. 6710188 / 6680065

Driving trolley

Material Wheel Travelling Rail Art.-No. speed

plastic / steel (galvanised) steel (galvanised) by hand CRL-1 6710188

CRL-2 6680065

391

308

78


Our Carrying trolleys are available for the „CRL-1“ as well as for the „CRL-2“ rail systems. They are used for workshop equip-ment, for example welding courtains.

CARRYING TROLLEYfor CRL-1 or CRL-2 Rail System

Art.-Nr. 6610202 / ...203 / ...204 / ...205

3

4

Carrying trolley

Material Wheel Payload Traveling Rail Art.-No. speed

steel (galvanised)

5 kg CRL-1 6610203

steel (galvanized) 15 kg

by hand CRL-2 6610205

plastic

3 kg CRL-1 6610202

10 kg CRL-2 6610204

Ø 24

Ø 33

46

35

45

35

Ø 9

Ø 9

20

25


Towing attachement for direct mounting onto a „CRL-1“ and „CRL-2“ cable trolley.

TOWING ATTACHEMENTfor CRL-1 or CRL-2 Cable Trolleys

Art.-Nr. 6610037 / 6610038 / 6610101 6600866

CRL-1 towing attachement

Material Wheel Art.-No.

steel (galvanised) plastic 6610037

steel (galvanised) 6610038

CRL-1 towing attachement plastic


plastic plastic 6600866

CRL-2 towing attachement


steel (galvanised) steel (galvanised) 6610101

125

29 40

R20

6320

2920

Ø24

Ø33

125

40

R20

63

98

57

70


C-Rail-Profiles - the basic component for your system. The standard length is 6 m.

C-RAILfor CRL-1 or CRL-2 Rail System

Art.-No. 52681 / 25042 52701 / 47822

CRL-1 Rail

Material Art.-No.

steel (galvanized) 52681

stainless steel (1.4571) 25042

CRL-2 Rail

Material Art.-No.

steel (galvanized) 52701

stainless steel (1.4571) 47822

4032

30

12

26

2,52

40

14

32


Ceiling and wall suspensions for „CRL-1“ and „CRL-2“ rail systems.

CEILING-/WALL SUSPENSIONfor CRL-1 or CRL-2 Rail Systems

Art.-Nr. 6610003 / 6610006 6610004 / 6610007

Ceiling installation

60

M8 M8

M8 M8

M12M10

32

30 40

40

3040

40 60

30

6060

33

6032

8 8

max.12 max.12

25 - 35 30 - 36

Material Rail Art.-No.

steel (galvanized) CRL-1 6610003

CRL-2 6610006

Wall installation

Material Rail Art.-Nr.

steel (galvanized)

CRL-1 6610004

CRL-2 6610007


As a component the traverses serve in combination with the clamps for the side mounting of „CRL-1“ or „CRL-2“ C-rails to existing beams.

Please select the corresponding traver-ses and clamps depending on the required rail system.

Clamps

Clamp width (a) Art.-No.

8 - 16 mm 910187

16 - 30 mm 910188

CRL1-Traverse

Traverse length Drilling Art.-No.

300 mm 1910039

400 mm 1910040

600 mm 11 mm 1910099

800 mm 1910090

1000 mm 1910091

CRL2-Traverse

Traverse length Drilling Art.-No.

300 mm 1505927

400 mm 1505928

600 mm 13 mm 1505930

800 mm 1505931

1000 mm 1505932

300 - 1000

M10 15

11

a

300 - 1000

M10 15

13

a

40 25

TRAVERSE & CLAMPfor CRL-1 and CRL-2 Rail Systems

Art.-No. 1910039 / ...40 / ...90 / ...91 / ...99 1505927 / ...28 / ...30 / ...31 / ...32 910187 / ...188


RAIL JOINTSfor CRL-1 or CRL-2 Rail System

Art.-No. 6710182 / 6610008 6610009

Rail joints

Material Size Rail A

100 mm

CRL-1 6710182

steel (galvanized) 120 mm CRL-1 6610008

120 mm CRL-2 6610009

31

40

40 120

30

32 1203310015

M8

M8

M10

M8

M8

Rail joints for „CRL-1“ and „CRL-2“ rail systems.


Rail stopper and end caps for „CRL-1“ and „CRL-2“ rails to complete your C-rail systems.

RAIL STOPPER and END CAPSfor CRL-1 or CRL-2 Rail System

Art.-No. 6610010 28801 / ...11

Rail stopper


steel(galvanized) CRL-1 und CRL-2 6610010

End caps


plastic CRL-1 28801

CRL-2 28811

M8

40

30

30

40

40

20

195

5


The wall traverses are a basic component for lateral wall mounting of the „CRL-1“ or „CRL-2“ C-rail systems. Please choose the according traverse length depending on the required wall distance.

WALL TRAVERSEfor CRL-1 and CRL-2 Rail Systems

Art.-Nr. 57629 / ...30 / ...31 / ...33 / ...34

Wall traverse

Length Material Art.-No.

300 mm 57634

400 mm 57633

600 mm steel (galvanised) 57631

800 mm 57630

1000 mm 57629

300 - 1000

80

27

50

13

13

7

140


CRL-1 / CRL-2 C-RAIL SYSTEMSystem Design

SYSTEM DESIGN

Cable trolleyDetermination of the ideal kind of cable trolley basedon type of cable/hose in considiration of the amountand weight of the cables /hoses. The additional weight of transported goods (e.g. water, oil) in hoses, needs to be considered.

SYSTEM CALCULATIONS

Cables / HosesDetermination of the required cables or hoses.

SagDetermination of the sag based on the available space.Local circumstances (Avoid contact with fixed equipment in operation area.)Curved sections (In curved systems the sag has to be smaller than ¹/³ of the curve radius.)We reccomend a sag of 300 mm up to 2000 mm. The bigger the sag, the less cable trolleys are needed.

Recommended ambient temperaturefor plastic cable trolleys: - 30 °C up to + 50 °Cfor steel cable trolleys: - 30 °C up to + 80 °C

Cable / hose lengthDetermination of the cable or hose lengthtrough adding up the following distances:▪ Connection point → end support▪ Staking length + 10%▪ Travelling distance + 10% ▪ Towing attachment → consumer

RailDetermination of the rail based on thechosen cable trolley type.

Number of cable trolleysDetermination the number of cable trolleysbased on the travelling distance and the sagby the following formula: travelling dist. (mm) Number of trolleys = 0,55 x ——-------—————— + 2 sag (mm)

The result already includes the towing attachement and the end support - round up to the next highervalue if necessary.

System lengthDetermination of system length trough adding up thetravelling distance and staking length (cable trolley length x amount) 1% in addition for safety.

Travelling distanceDetermination of the travelling distance.

1

2

3

4

5

6

7

8

—————————————————————————Cable / Hose Weight/m (kg)

█ █ █ █ █ █ █ █ █ █ █ █ —————————————————————————

Cable trolley type Length (mm)

█ █ ————————————————————————— Length (mm)

Sag █ ————————————————————————— Length (mm)

Travelling distance █ —————————————————————————Total amount cable trolleys (rounded up)

█ travelling distance in mm 0,55 x ———————————————— + 2 █ sag in mm

Number (pieces): █ Total length (mm): █ —————————————————————————System length (mm) █ travelling distance + staking length plus 1%

—————————————————————————Cable / hose length

Anschlusspunkt → Endtrage █ Staking length + 10% █ Travelling distance + 10% █ Towing attachement → consumer █ Total length (mm): █ Total weight (kg): █ —————————————————————————Rail Length (mm)

□ CRL-1 / □ CRL-2 █ —————————————————————————


CRL-1 / CRL-2 CABLE FESTOON SYSTEMSet up of a C-Rail System

Travelling distance

65

Joints

SuspensionCable trolley

End supportCRL - Rail

End capRail stopper Towing attachement

End cap

5

= x A²

A²

= x A³

A¹ A¹ A³

5

Staking distance

Mounting distance A¹ Mounting distance A² Mounting distance A³

For both systems, CRL-1 and CRL-2, the first „Travelling area“ „Staking area“suspension is installed in a distance of 200 mm Maximum suspension distance: Suspension distance: to the lateral C-rail end. CRL-1 System = 1500 mm CRL-1 System = 750 mm CRL-2 System = 2500 mm CRL-2 System = 1250 mm

Note: The end caps are 15 mm deep in the C-rail profile after assembling. We reccomend to fix the rail stoppers directly behind the end cap. The C-rail profiles are available in a 6 meters standart length and are firmly connected with the according joints. Please have a look at the data sheets for exact measurements.

CRL-1 / CRL-2 CABLE FESTOON SYSTEM - STEMMANN · CRL-1 / CRL-2 CABLE FESTOON SYSTEM Set up of a...

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