Operating and Maintenance

Instructions
for
KABELSCHLEPP Cable Drag Chains
with Steel Chain Bands
 Table of Contents Page

Preface 2

1.00 Definition of terms 3

2.00 Transport and storage 4

3.00 Erection of the cable drag chains 5

Connection of the cable drag chain 6

4.00 Instructions
for the installation of cables and hoses 8

5.00 Maintenance of the cable carrier system 10

6.00 Installation of support roller(s) 11

7.00 Spare parts list

Cable drag chains with steel chain bands
Standard application 12

7.10 Spare parts list

Cable drag chains with steel chain bands
Chain plate application 13
Edition:
GB - 08.1995 8.00 Annex 14

1
Preface

This operating manual shall facilitate the erection and

maintenance of KABELSCHLEPP - cable drag chains; it
is therefore indispensable to give it your's very careful
consideration.

This operating manual is valid for all KABELSCHLEPP -

cable drag chains.

The operating manual is intended for persons being char-

ged with the erection and maintenance of this product.

Will you please hand this operating manual over to the

personnel concerned.

The maintenance work must be carried out attentively

and in due time in order to preserve the longevity of the
KABELSCHLEPP - cable drag chains.

The information and the drawings given here in must

not be duplicated without our approval, not utilized abu-
sively or brought to the notice of a third party.

We reserve to ourselves the copyright in this description

and operating manual.

The technical data of the KABELSCHLEPP - cable drag

chains, shown in this operating manual, are subject to
modifications in the frame of development.

2
1.00 Definition of terms Generaly:

LS = max. travel length of the driver

LK = length of the cable drag chain
KR = bending radius of the cable carrier system
BK = width of the cable drag chain
H = connection height
z = pre-tension
Hz = clearance height allowing for pre-tension
Lf = self-supporting length
hG = link height
tG = chain pitch
LFV = offset length between fixed point of the cable
drag chain and the travel center

Support tray:

LA = length of the support tray

b1 = clear width of the support tray
BA = width of the support tray
hA = height of the support tray
s = sheet thickness

with support:

aR1 = distance between the first support

and the fixed point
aR2 = distance between the supports respectively
between the second support and the driver
b1 = clear width of the support
bE = clear width between the trestles
bG = total width of the support
HA = axle height of the support

3
2.00 Transport and Prior to the delivery, KABELSCHLEPP - cable drag
storage chains are subject to a careful quality control.

The cable drag chains are generally supplied in rolled

up condition.

The transport should take

place in such a way that
through the inner ring of
the cable drag chain, a
square piece of wood is
pushed to which lift wires
are fastened on both sides.

For unloading and during transport respectively, please

thake care that the chains will not be damaged by a
rough treatment (pushing, throwing etc.)

The cable drag chains can be stored in piled or rolled

up condition, lying down or upright.

They must be protected absolutely against negative

environmental influences (dust, dirt, humidity etc.)

It is for this reason, that storage must take place in

closed and dry rooms only.

4
3.00 Erection of the Prior to the commencement of the erection, the actual
KABELSCHLEPP length of travel of the installation is examined. It results
cable drag chains from the distance of the movable consumer in the spe-
cific end positions.

fixed driver
point

support tray

schema of motion
self-supporting arrangement

If the centre of the travel length is the same point at

which the fixed connection (fixed point) of the cable drag
chains takes place, the necessary length of the cable
drag chain results from the formula:

LS
LK = + KR . π + 3 tG Dimensions in mm
2

If the fixed point of the cable drag chains lies outside of

the centre of travel length, the necessary length for the
cable drag chain is calculated as follows:

LS
LK = + KR . π + 3 tG + LFV Dimensions in mm
2

The length LK of a cable drag chain, supplied for a cer-

tain requirement, must be checked in the light of these
formulae.

The bending radius KR of the cable drag chains should

be checked by you before installation.

The minimum bending radius is prescribed by the

manufacturer of the supply cables/hoses. Cooperative
lines can be taken from the appropriate VDA regulations.

5
Connection of the Operation sequence:
cable drag chains
Exact fixation and identification of the fixed point.

To guarantee optimum operation of the KABELSCHLEPP

cable drag chain, a clean flat surface should be provided.
If this is not possible then a trough is required.

Length of support tray:

LS
LA = + ÜB + l1
2

max.section length: 3000 mm

type b1 BA hA s
0650.1 BK + 15 BK + 40 30 2
0950 BK + 15 BK + 40 30 2
1250 BK + 20 BK + 60 50 3
1800 BK + 20 BK + 60 50 3
1250 BK + 25 BK + 75 80 3
1800 BK + 25 BK + 75 80 3

The trough must be exactly in line with the machine and

the driver connection.

Fastening of the trough on the surface (foundation or

supporting design).

Lay out the cable drag chain in such a way that the ben-
ding side lies upwards and the rigid side downwards.

Pull up the cable drag chain over the bending side in

order to determine the position of the driver connection.

The driver joins the connecting angles of the cable drag

chain with the movable unit.

The driver connection must be manufactured in such a

manner that it reaches over the entire width of the cable
drag chain.

The length of the driver connection results from the

width of the cable drag chain and the lateral distance of
the chain to the movable unit.

6
The minimum connection height of the cable drag chain
amounts to:

Hmin = 2 KR + hG + 20 mm

On no account, the connection height must be carried

out lower.

The required clearance height for the operation of the

cable drag chain amounts to:

Hz = 2 KR + hG + z

The pre-tension z = approx 8 mm/m

of cable drag chain length.

After having fastened the connecting angles at the dri-

ver connection, the upper- and lower lump of the cable
drag chain must stand centrically in-line over one
another.

For different travel speeds of the movable unit (forward

and return stroke), the cable drag chain should be con-
nected in such a manner that during the travel with the
higher speed, the cable drag chain is drawn.

7
4.00 Instructions The cables and hoses have to be installed carefully in cable drag
for the installation of chains and flexible energy conduits.
cables and hoses

Principally it is to be considered:

Only those electrical cables should be installed, which are suitable

for the application in cable carrier systems.
Please ask KABELSCHLEPP or the manufacturer of cables/hoses
for information concerning the cables/hoses in question.
The hoses should have a high flexibility and only a little length
variation (shortening or lengthening) is admissible under pressure.
You will find information of lengthening characteristics of hoses in
the respective manufacturer's catalogue.

The cables/hoses have to be istalled twist-free in the cable carrier

system!
Cables have to be payed-off tangentially from coils an drums.
Never take up cables in loops!

Whenever possible the cables/hoses have to be installed separately

and loosely side by side!
divider It is to avoid to install several cables/hoses having different diame-
ters on top of each other resp. side by side. If cables/hoses are
installed on top of each other, separators should be provided
between them.
It is advantageous to install each cable/hose in a separate chamber.
Individually manufacatured hole stays or the separation by dividers
in frame stays avoid the friction of cables/hoses installed side by
side.
separator If unavoidable to install several cables/hoses side by side without
dividers, it is to be considered that the remaining free passage
height is smaller than the cable/hose diameter. Only in such a way
a twisting of the cables/hoses can be avoided.

electrical cable hose flat cable

The cables/hoses must be loosely installed in the cable carrier
system. They should neither be fixed nor tied together in the cable
carrier system.
Principally separators have to be provided between flat cables
being installed on top of each other.
For dimensioning the necessary clerance see the following stan-
dard values:
hole stay frame stay for round cables 10 % of the cable diameter
for flat cables each 10 % of the cable width res. thickness
for hoses 20 % of the hose diameter

8
 protection hose
High flexible cables/hoses with a small flexural resistance have to
be installed loosely bunched and fitted in a protection hose.
The cross-section of the protection hose must be considerably lar-
ger than the sum of the single cable/hose cross-sections.
The standard value for dimensioning the cross-section is: each
cable/ hose needs about 10% of its diameter as clearance.
The weight distribution in the chain stay resp. in the conduit cross-
section should be as symmetrical as possible!

Independent of the kind of distribution in the chain stay cross-sec-

tion the following is valid:
Hoses under pressure must be freely movable, because they
shorten or lengthen themselves under load of changing
pressure!
A shortening or lengthening of the hoses can only be compensated
hole stay frame stay within the loop of the bending radius.
The necessary clearance can be calculated depending on the pro-
portional modification. (producer indication)

It is to be considered that the cables/hoses move in the bending

radius KR without any constraint.

In multilayer application the cables/hoses must be installed in the

cable carrier system in such a way that there will be sufficient
clearance between them when bending occurs.

The fixing of the cables/hoses depends on the type, the length of

the cable carrier system and the fitting position:
Cables/hoses with high flexibility and a low inherent stability
have to be fixed at the fixed point and the driver. Otherwise
there is a danger that they squeeze through the chain stays.

Even in case of vertical suspended arranged cable carrier

systems the cables/hoses have to be fixed at the fixed point
and the driver.

In case of travel lengths within the self-supporting range of the

cable carrier system electrical cables should preferably be non-
tensioned at the driver and the fixed point.

In case of longer travel lengths the cables should be non

tensioned only at the driver. (Except for cables with inherent
stability)

Pressure hoses with end screwed connections, which are

bolted in the immediate vicinity of the driver and the fixed point,
do not have to be nontensioned. If the screwed connection is
"more distant", it is recommended to install a tension reduction
analogous to the cables.
Generally it is important that the pressure application takes
place only extensively on the outside coating so that the
single leads of electrical cables cannot be squeezed and a dis-
placement of the cables is not possible!

9
5.00 Maintenance All bands of the cable drag chains in standard design
of cable carrier system are surface galvanised, the hole stays are supplied in
aluminium.

The material of the cable drag chains can be adapted to

individual requirements with regard to specific environ-
mental influences, for instance stainless steel.

The links of cable drag chains do not have greasing

spots.

Therefore the KABELSCHLEPP - cable drag chains are

practically maintenance free!

If, however, the cable drag chains are permanently ex-

posed to extraordinary environmental influences (bad
pollution etc.), it is expedient to clean them in short
intervals.

In case of humidity influences, the standard cable drag

chains should be subsequently treated with adequate
methods.

The support for the cable drag chains should be

constantly kept clean.

In installed condition, the standard cable drag chains

are not ascendable.

10
6.00 Installation
of support roller(s)
If the actual unsupported length is higher than the maxi-
mum admissible unsupported length of the applied
chain type, the upper lump of the cable drag chain must
be supported.
Please take care that the support roller(s) are mounted
in line in the centre under the upper lump.

Arrangement with one support:

LS =
^ 3 Lf zul

LS The distance between the roller

aR1 = and the fixed point is approx. 1/6
6
of the length of travel

Arrangement with two supports:

LS =
^ 4 ( Lf zul - 150 mm)

LS
aR1 = 300 mm aR2 = + 150 mm
4

First roller 300 mm away from the fixed point.

Second roller in the centre of the remaining
unsupported length.

Cross section A - B Cross section C - D

PR
B
A
DR

type DR b1 bE bG HA A B PR
0650 120 Bk + 15 Bk + 59 Bk + 169 2KR- 60 140 180 U80
0950 120 Bk + 20 Bk + 64 Bk + 174 2KR- 60 140 180 U80
1250 120 Bk + 25 Bk + 69 Bk + 179 2KR- 60 140 180 U80
1800 120 Bk + 30 Bk + 74 Bk + 184 2KR- 60 140 180 U80
2500 220 Bk + 30 Bk + 74 Bk + 184 2KR- 110 160 200 U100
3200 220 Bk + 30 Bk + 74 Bk + 184 2KR- 110 160 200 U100

11
7.00 Spare parts list
for cable drag chains with steel chain bands
Standard application

Stay at each 2nd link

Stay at each 2nd link

Ident-No.
Part Description
Typ 0650.1 Typ 0950 Typ 1250 Typ 1800
1 Chain link *) 44450 42440 43255 43892
2 Bolt 29910 29920 29930 29950
3 Circlip 27710 27720 27730 27780
4 Stay screw 21960 21980 21980 22170
5 Hole stay To suit requirements!
6 Clip 36050 36060 36060 36070
7 Frame stay To suit requirements!
8 Frame stay end piece 41530 42200 42920 ---
9 Divider / double divider 44250 42160/42130 42900/42880 43810
10 Connecting piece r.h. 44210 42100 42850 43750
11 Connecting piece l.h. 44215 42105 42855 43555

*) When ordering chain links, the chain type and bending radius (shown on the serial plate) must be stated!

12
7.10 Spare parts list
for cable drag chains with steel chain bands
Chain plate application (galvanized)

Stays at every outer chain plate

11

12
2

1
10
4+5

9 6 8
7

Ident-No.
part description
type 1252 type 1802 type 2500 type 3200

1 Outer chain plate 50000 50200 43960 50300

2 Inner chain plate *) 50115 50214 43966 50320
3 Intermediate piece 50130 50260 43980 50325
4 Intermediate mounting screw 19640 19810 19920 19930
5 Intermediate mounting nut 27060 27090 27110 27110
6 Bolts for chain plates 29930 29940 29960 29965
7 Bolts for connecting pieces 29930 29940 29962 29967
8 Circlip 27730 27765 27790 27796
9 Connecting piece left 42850 50255 43992 50335
10 Connecting piece right 42855 50250 43990 50330
11 Hole stay To suit requirements!
12 Stay clamp 36060 36070 ---- ----

*) When ordering chain plates, the chain type and bending radius (shown on the serial plate) must be stated!

13
8.00 Annex
Chain cross section
Technical data etc.

14
For further questions:

KABELSCHLEPP
.
GMBH
D-57074 Siegen Marienborner Straße 75
D-57006 Siegen . Postfach 10 06 54
Telefon (0271) 5801-0 . Telefax (0271) 5801-220
http://www.kabelschlepp.de . e-mail: info @ kabelschlepp.de