technical data sheet media supply system besta'power … … · w5–traxx tdb0489-0001d-e...

Technical Data Sheet Media Supply System Besta'Power W5–traxX

TDB0489-0001d-E www.conductix.com Translated document of 31

Order-Number 0489xx-xxxx



Index Page 1 Product Description ........................................................................................................................................................................ 3 2 Specifications ................................................................................................................................................................................. 4 3 System Component Overview ........................................................................................................................................................ 5

3.1 Aluminum profile .......................................................................................................................................................... 7 3.1.1 Attachment concept ..................................................................................................................................................... 8 3.1.2 Profile lengths and compressed air outputs ................................................................................................................ 9 3.1.3 Load diagram (spot load) ........................................................................................................................................... 10 3.2 Profile end feeds ........................................................................................................................................................ 11 3.3 Outlet of compressed air ........................................................................................................................................... 12 3.4 Profile end cap ........................................................................................................................................................... 13 3.5 Profile connector ........................................................................................................................................................ 14 3.6 Suspension ................................................................................................................................................................ 15 3.7 Trolleys ...................................................................................................................................................................... 16 3.7.1 Single trolley .............................................................................................................................................................. 16 3.7.2 Traverse trolley .......................................................................................................................................................... 17 3.8 End stop .................................................................................................................................................................... 18

4 Media supply ................................................................................................................................................................................ 19 4.1 Energy guiding chain with guiding channel ............................................................................................................... 20 4.1.1 Pressure drop ............................................................................................................................................................ 21 4.1.2 Chain set with supply lines ........................................................................................................................................ 22 4.1.3 Guiding channel, 2 m standard .................................................................................................................................. 24 4.2 Festoon system ......................................................................................................................................................... 25 4.2.1 Festoon system for compressed air or compressed air and electric lines ................................................................. 26 4.2.2 Flow characteristics for 1/2” and 3/8” hose ................................................................................................................ 27 4.3 Spiral hose system with cable guide ......................................................................................................................... 28 4.3.1 Spiral hose system with cable guide for compressed air ........................................................................................... 28 4.3.2 Flow characteristics for 1/2” and 3/8” spiral hose ...................................................................................................... 29

5 Accessories .................................................................................................................................................................................. 30 5.1 Tool transporter ......................................................................................................................................................... 30 5.2 Reels and retractors .................................................................................................................................................. 31 5.3 Compressed air accessories ..................................................................................................................................... 31



1 Product Description The Besta'Power W5-traxX system integrates compressed air lines in its aluminum load profile and provides moving users with a continuous supply of compressed air, electrical energy, and data over energy guiding chain or festoon system. The modular assembly and flexible attachment system allows for simple and quick installation as well as flexible upgrades or modifications. The double O-ring seals and innovative compressed air outputs provide maximum dependability and tightness. Standard fall protection on the trolleys and screw joint retention using special coating provide the highest level of safety. Main features of Besta'Power W5-traxX: • Loading capacity: 100 kg with a maximum suspension interval of 4 m • Integrated 2” compressed air pipe • Standard 1/2” compressed air outputs every 2 m • Flexible attachment of components provided by clamping profiles on all sides • Secure and simple guiding with flanged rim wheels • Standard fall protection on trolleys • Safety due to special coated screws



2 Specifications Loading capacity/suspension interval 100 kg point loading at 4 m intervals (see graphic page 12) Load profile surface Anodized aluminum Maximum operating pressure 12 bar Medium dry, or oiled compressed air Usage location interior zone Process temperature +5 °C to +60 °C Feed 2“ ball valve with external threading Integrated compressed air pipe 2“ internal diameter Output 1/2“ ball valve with internal threading every 2000 mm Flow characteristics depends on interfaces, see pages 21, 27, 29 Media supply Energy guiding chain with guiding channel Cable trolleys with hose / cable (festoon system) Spiral hose with cable guide Trolleys Standard trolleys (length: 400, 600, 800 mm) Standard fall protection Polyamide flanged rim wheels Custom trolleys and tool transporters on request



3 System Component Overview

1. Profile connector 4. Profile end feed 2. Profile end cap 5. Suspension clamp 3. Compressed air output 6. End stop



3 different media supply systems are available to complement the W5-traxX profile.

Energy guiding chain with guiding channel

Festoon-System

Spiral hose with cable guide



3.1 Aluminum profile The W5-traxX profile is a compact aluminum load profile for stationary and continuous media supply that has been specifically designed to meet the requirements of mechanical handling and assembly. The integrated 2” compressed air tube provides for minimal pressure loss, allowing for economical compressed air delivery to the entire workspace. Material: Aluminum, anodized Measurements: 152 x 70 mm Single profile length: max. 6000 mm (see table p.11) Running surface: I-beam Attachment: dovetail clamps on all sides adaptable t-notch 20x7 mm The individual profiles can be joined using the double-sealed profile connector to create nearly any system length. Standard 1/2" compressed air outputs are located at intervals of two meters to allow for flexible arrangement of workspaces and assembly cycles.



3.1.1 Attachment concept Using universal clamping brackets with a dovetail profile, additional components can be added to the side, the top or the bottom at any time. The interface used here is an attachment unit for T-slot nuts or M8 hammerhead bolts. The attachment units are available in customized variations.

1. Universal clamping unit 2. Attachment unit 3. Possible locations on the load profile for adding components



3.1.2 Profile lengths and compressed air outputs The standard configuration provides for compressed air outputs with 1/2" mini ball valves, installed at 2-m-intervals. The exact measurements for various profile lengths can be found in the following table:

Total length mm No. of outputs L1

mm L2

mm L3

mm Order

number

6000 0 - - - 048900

6000 3 1000 3000 5000 048901-001-6,0

4000 2 1000 3000 - 048901-001-4,0

2000 1 1000 - - 048901-001-2,0

Output interface: ball valve with 1/2” internal threading



3.1.3 Load diagram (spot load)

The graphic shows the maximum suspension intervals with a maximum deflection of 1/500 of the suspension distance. Heavier loads are possible, but the maximum deflection of 1/500 of the suspension distance will be exceeded. The explicit written permission of Conductix-Wampfler is required for the use of heavier loads or longer suspension intervals than shown in the graphic.

load diagram W5-traxX

0

1

2

3

4

5

0 50 100 150 200 250 300

load in kg

susp

ensi

on d

ista

nce

in m



3.2 Profile end feeds Order No.: 048913 The standard interface for compressed air input is a ball valve (DN50) with G 2" external threading. A double O-ring seal and a grooved drive stud guarantee tightness and operational safety.

1. Feed bushing 6. O-rings 2./3. End cover plates 7. Sheet metal screw 4. Clamping element 8. Grooved drive stud 5. 2” ball valve with external threading



3.3 Outlet of compressed air Order No.: 048920-001 The interface for compressed air supply uses a 1/2" mini ball valve with internal threading. The compressed air output is attached to the profile with a clamping element and is sealed with an O-ring. The standard profile configuration is delivered with compressed air outputs at 2-m-intervals.

1. Clamping element 3. Compressed air output 2. 1/2” mini ball valve with internal threading 4. O-ring



3.4 Profile end cap Order No.: 048910 The end of the aluminum profile line is closed with double-sealed end caps. A double O-ring seal and a grooved drive stud for safety guarantee tightness and process safety.

1. End cover plate 5. End cap screw 2. Profile end cap 6. Sheet metal screw 3. Clamping elements 7. Grooved drive stud 4. O-rings



3.5 Profile connector Order no. 048915 The profile connector serves to connect 2 profiles endwise. It is used to create longer systems. The joint is sealed with double O-rings on both sides to allow for maximum tightness.

1. Connector bracket 3. Connector pin 2. Connector bushing 4. O-rings



3.6 Suspension Various suspension devices are available for attachment to existing steel beams at the customer’s facility. Solutions are available for both parallel and transverse steel beam arrangements. For parallel I-beams For transverse I-beams Order No.: 048960 Order No.: 048960-001 Up to IPE 240 Up to IPE 200 Other sizes on request Other sizes on request

1. Attachment unit 1. Attachment unit 2. Suspension brace 2. Clamping bracket 3. Clamping bracket 4. Bracket arm



3.7 Trolleys Besta'Power W5-traxX allows various types of trolleys to be used for different applications. Single and traversing trolleys form the interfaces for media supply (energy chains, looped cables, spiral hose systems). The Besta'Power W5-traxX trolleys are designed to be extremely soft-running. Thanks to the innovative aluminum load profile, flanged rim wheels can be used that serve as guide rollers as well as counter-pressure rollers. End stops are required for trolley use in order to limit the operating range. Feature summary of the W5-traxX trolleys at a glance:

• Soft running thanks to polyamide (PA) flanged rim wheels • Highest level of security thanks to standard fall protection • Interfaces for media supply (energy chain, looped hose/cable, spiral hose with cable guide) • Very flexible, thanks to customer-specific combinations with traverses, tool transporters, load trolley, etc. • Collide gently thanks to rubber buffers 3.7.1 Single trolley Order No.: 048950

Loading capacity: max. 50 kg Rollers: Polyamide flanged rim wheels



3.7.2 Traverse trolley Order No.: 048955-0460 The Besta'Power W5-traXX traverse trolley offers infinite possibilities for use at assembly workstations. A compressed air distributor is integrated in the aluminum traverse so that all consumer applications can be optimally supplied. For use with items such as the tool transporter (see accessories, p. 34 below): Loading capacity: max. 100 kg Rollers: Polyamide flanged rim wheels Traverse length: 400 mm (standard); 600 mm, 800 mm, customer-specific Compressed air interfaces: 1 pivoting 1/2” feed for items such as the chain module, 2 x 1/2” outputs (equipped with plugs)

1. Single trolley 2. Traverse with integrated compressed air distributor 3. 1/2” feed for items such as the chain module



3.8 End stop Order No.: 048925 The end stop for the Besta'Power W5-traxX serves to limit the workspace and is necessary for the use of trolleys. The end stops can be positioned at any point along the load profile using a clamping system.

1. End stop 2. Clamping element



4 Media supply 3 different media supply systems are available for W5-traxX. Energy guiding chain with guiding channel (Page 20) • For compressed air, electric and data lines • No cable slack • No retraction force • Higher flow • Minimal pressure loss Long workspace Tools with high compressed air consumption Festoon system (Page 25) • For compressed air, electric and data lines • Cable slack • Cable depot • Minimal retraction force • Moderate flow • Moderate pressure loss Medium-sized workspace Tools with minimal compressed air consumption Spiral hose with cable guide (Page 28) • Minimal cable slack • Cable depot • Large retraction force • Minimal flow • High loss of pressure Short workspace Tools with minimal compressed air consumption



4.1 Energy guiding chain with guiding channel The chain’s guiding channel allows for the continuous media supply to the entire workspace. In addition to compressed air hoses, electric and data lines can be safely guided to the user.

The use of energy guiding chains frees the area around the worker's head from distracting cable slack. The energy guiding chain feed at the center of the operating range allows for more efficient use of compressed air than with normal festoon systems or spiral hose applications, as shorter hoses can be used.



4.1.1 Pressure drop The graphic below shows the pressure drop of an energy chain using a 1/2” compressed air hose with an operating pressure of 7 bar. The pressure drop between trolley and consumer or other downstream systems must be added to this in each case.

Chain/Channel System: dynamic pressure drop

0

10

20

30

40

50

60

70

80

90

100

110

8 16 24 32 40 48 56 64 72 80

air flow in cubicfeet/minute

dyna

mic

pre

ssur

e in

psi

Hose length: 9.8 ft (Work area 19.6 ft)

Hose length: 19.6 ft (Work area 39.4 ft)

Hose length: 29.5 ft (Work area 59 ft)



4.1.2 Chain set with supply lines In general, a chain set includes the energy guiding chain with supply lines (standard or customer-specific) and the necessary elements to attach the chain.

Depending on the supply lines in the energy guiding chain, the large volume of the energy guiding chain may allow for later additions. The following standard chain sets are available for the given traverse lengths:



4.1.2.1 Compressed air chain set Order No.: 048935-XXX Length: Chain is adjusted to fit the operating range Outside measurements, chain: 79 x 35 mm Inside measurements, chain: 62 x 26 mm Minimum bending radius: 50 mm Material: PA Compressed air hose: Internal diameter 1/2” Consists of the following: • Chain, length based on operating range • 1/2" hose, about 2.0 m longer than the chain, can be cut during assembly • Accessories for attaching the energy chain 4.1.2.2 Compressed air / Electric chain set Order No.: 048935-XXX Length: Chain is adjusted to fit the operating range Outside measurements, chain: 79 x 35 mm Inside measurements, chain: 62 x 26 mm Minimum bending radius: 50 mm Material: PA Compressed air hose: Internal diameter 1/2” Cable: 3 x 1.5 mm² or 5 x 2.5 mm² (other configurations on request) Electrical feed: Terminal box at center of operating range Electrical output: Terminal box on trolley Consists of the following: • Chain, length based on operating range • 1/2" hose, about 2.0 m longer than the chain, can be cut to length during assembly • 1/2" cable, about 2.0 m longer than the chain, can be cut to length during assembly • Terminal box with attachment elements • Accessories for attaching the energy chain Length of operating range and chain contents can be tailor-made to customer specifications!



4.1.3 Guiding channel, 2 m standard Order No.: 048930-XXX The guiding channel serves to host and guide the energy guiding chain. The number of guiding channels needed is based on the operating range. The guiding channel segments are attached endwise using a connection plate. To install the channel, plastic clips (polyamide) are used to fasten the brackets quickly and easily on the aluminum profile. Optional, an additional plate (without illustration) can be used to avoid the lifting of the chain at high speed movements. Technical specifications guiding channel Length: L = 2000 mm Material: Powder coated steel Color: Guiding channel yellow Attachment: gray / black

1. Guiding channel 2. Connection plate 3. Attachment bracket 4. Mounting clips



4.2 Festoon system For medium operating ranges and low compressed air usage, a festoon system can be used for media supply. Every festoon system tends to be fixed in a neutral position and move without operator input due to the retraction force of the lines. Additionally, a cable depot of approx. 10% of the operating range is needed as a buffer zone for the trolleys (with cable slack of approx. 600 mm).

1. Cable trolleys 2. End stop 3. Cable loop 4. Cable components (connections, hose clip, etc.)

1

4

3

2

1

4



4.2.1 Festoon system for compressed air or compressed air and electric lines The length of the hoses/the cable and the cable slack are adjusted to fit the workspace. Technical Data Trolley length: 110 mm Cable depot: about 10% of the trolley path / operating range Slack: min. 600 mm Material: Cable trolleys: plastic Rollers: PA Cable holder: plastic Hose diameter: 1/2” or 3/8” Optional electric line Cable: 3 x1.5 mm² 5 x 2.5 mm² others on request Electrical connection: Terminal box at start end of operating range Terminal box on trolley



4.2.2 Flow characteristics for 1/2” and 3/8” hose The graphic below shows the pressure drop of an energy chain using a 1/2” or 3/8” compressed air hose at an operating pressure of 7 bar. The pressure drop between trolley and consumer or other downstream systems must be added to this in each case.

Festoon system: dynamic pressure drop

0

20

40

60

80

100

8 16 24 32 40 48 56 64 72 80


dyna

mic

pre

ssur

e in

psi

1/2'' - Hose length: 29 ft(Work area 19.6 ft)


1/2'' - Hose length: 88 ft(Work area 59 ft)



3/8'' - Hose length: 88 ft(Work area 59 ft)



4.3 Spiral hose system with cable guide A spiral hose system with a cable guide represents yet another solution for continuous media supply. Just like the festoon system, this type of system tends to move towards a central position. The retraction force of the spiral hose should be kept in mind. A cable depot is also necessary with this type of system, which may constrict the workspace. 4.3.1 Spiral hose system with cable guide for compressed air The length of the hose and the cable slack are adjusted to fit the workspace. Technical Data: Cable diameter: 4 mm Cable depot: about 10% of the trolley path / operating range Material: Steel cable with plastic coating Mount: Powder coated steel Hose diameter: 1/2” or 3/8” Hose spiral: Outside diameter 150 mm

1. Cable mount 3. Spiral hose 2. Steel cable



4.3.2 Flow characteristics for 1/2” and 3/8” spiral hose The graphic below shows the pressure drop of a spiral hose system using a 1/2” or 3/8” compressed air hose at an operating pressure of 7 bar. The pressure drop between trolley and consumer or other downstream systems must be added to this in each case.

Spiral Hose System: dynamic pressure drop

0

20

40

60

80

100

8 16 24 32 40 48 56 64 72 80


dyna

mic

pre

ssur

e in

psi

1/2'' - Hose length: 29 ft(Work area 19.6 ft)1/2'' - Hose length: 59 ft(Work area 39.4 ft)1/2'' - Hose length: 88 ft(Work area 59 ft)3/8'' - Hose length: 29 ft(Work area 19.6 ft)3/8'' - Hose length: 59 ft(Work area 39.4 ft)3/8'' - Hose length: 88 ft(Work area 59 ft)



5 Accessories 5.1 Tool transporter Trolleys can be equipped with tool transporters to meet customer specifications. The tool transporter configuration can be modified to fit the requirements of a workspace, including additional components such as hose reels, retractors or balancers. A wide range of tool holders is available. The frame is made of an aluminum profile or, optionally, of aluminum pipe.

1. Tray 5. Compressed air distributor 2. Tool holder 6. Power socket and plug 3. Storage compartments 7. Perforated sheet 4. Service unit



5.2 Reels and retractors Technical information regarding reels and retractors can be found in the Conductix-Wampfler catalog KAT0402-0002-E. 5.3 Compressed air accessories • Service units • Compressed air guns • Spiral hoses

technical data sheet media supply system besta'power … … · w5–traxx tdb0489-0001d-e...

Documents