The cable marshalling point (the profile end on which the festoon cable system is pushed together by the trolley) must be installed with a travel stop. This prevents the trolley from running to the very end of the HB profile rail and impacting the cable marshalling point with the cable sliders.

Installing the travel stop at the cable marshalling point:

  Drill a hole in the profile rail section on both sides for the travel stop:

─     Distance from the profile end: as calculated or taken from the planning documents.

─     Diameter 12 mm.

─     Distance to lower edge

─     If the travel stop lies in the area of a profile joint: drill through both the profile rail section as well as the clamping plates.

  Deburr the drilled holes.

  Thoroughly remove any saw or drill shavings.

Otherwise the shavings can clog the castors of the trolleys and impair their running.

  If the travel stop lies in the area of a profile joint: insert the bolt through the HB profile rail.

  If the travel stop lies on a free profile rail: place a spacer on the bolt and insert the bolt through the HB profile rail.

  Secure bolt with SL safety clip.

Calculate the number of cable sliders:

  Read off the cable sag from the crane drawing.

  Calculate and round off the number of cable sliders.

Insert cable sliders:

  Insert the corresponding number of cable sliders.

On the trolley lying in the direction of the power supply:

  Screw the bracket onto the trolley with the M8x25 rib screw. 20 Nm.

  Press the festoon cable system with cable support against the bracket. Screw tight with M6x40 hexagon head screws (2x) and M6 hexagonal nuts (2x).

  Lock with M6 hexagonal nuts (2x).

  Lay the festoon cable system from the end of the HB profile rail and fasten loosely at first with cable clips on the cable sliders.

For narrow, individual flat cables, push the cable clips in the narrow opening on the cable slider. For wide or multiple cables, use the wide opening.

  Position the cable sliders in such a way that two cable sliders are twice the cable sag away from one another.

The cable sag (usually 800 m) is specified on the crane drawing.

Depending on the total length of the flat cable, the cable sliders can also lie closer together. The spacing between all cable sliders should nevertheless remain the same.

  Tighten the cable clips.

Every HB profile rail must be fitted with end caps on the profile ends. These prevent dirt from penetrating the HB profile rail and also serve as an end stopper to prevent the HB crane or trolley from falling out of the HB profile rail.

The end cap remains the fixed point of the festoon cable system.

On the HB profile rail with festoon cable system:

  Insert cable sliders on the end cap.

  Push the spacer sleeve into the end cap.

Only with HB240: use the spacer sleeve with black coating. It is slightly longer than the spacer sleeve with silver or yellow coating.

  Put on the end cap.

If necessary, widen the HB profile rail slightly to enable insertion of the spacer sleeve.

  Insert a hexagon head screw through the HB profile rail and the spacer sleeve.

  Insert washer, screw on the self-locking M12 nut. 80 Nm.

  Fasten the flat cable as before on the fixed cable slider.

On all other HB profile rails:

  Push the spacer sleeve into the end cap.

Only with HB240: use the spacer sleeve with black coating. It is slightly longer than the spacer sleeve with silver or yellow coating.

  Put on the end cap.

If necessary, widen the HB profile rail slightly to enable insertion of the spacer sleeve.

  Insert a hexagon head screw through the HB profile rail and the spacer sleeve.

  Insert washer, screw on the self-locking M12 nut. 80 Nm.