catalog cable festoon

For the Electrification of:

● Overhead Cranes● Monorails● Transfer Cars● Trippers● Stacker / Reclaimers

Insul-8 Mobile ElectrificationCable Reels ◆ Conductor Bar ◆ Festoon ◆ Pendants ◆ Drives ◆ Slip Rings

Solutions From A Single Source

Cable FestoonSystems for Power and Control

This catalog showcases a sampling of themost commonly used festoon systems.If you don’t see what you’re looking for,please ask us.

FESTOONING SYSTEMS FROM INSUL-8 MOTIV-8TM

INSUL-8 CRANE ELECTRIFICATION

Typical C-Track Festoon Systems (Power & Control) For Overhead Crane Installation

21

43

5

16

17

1

2

3

4

5

6

7

8

15 14

13

12

6

7 8

9

10

11

Fixed End Junction Box

Terminal Strips (inside junction box)

Cable Connectors

End Clamp

Track Hanger Clamp

Intermediate Trolley

Cross Arm Support

Beam Clamp

Track

Control Box Trolley

Track Joint

Pendant Cable

Pendant Push-Button Station

Tow Arm

Tow Trolley

Flat PVC Cable

End Stop

9

10

11

12

13

14

15

16

17

1 Ph: 402-339-9300/800-521-4888 www.insul-8.com

✱ Insul-8 alsooffers a QuickDisconnectControl BoxTrolley

MOTIV-8TM FESTOONING SYSTEMS FROM INSUL-8

TABLE OF CONTENTS

2

THIS CATALOG PROVIDES A WIDE VARIETY OF FESTOONING SOLUTIONS FOR ELECTRIFYING OVERHEAD CRANES.

Ph: 402-339-9300/800-521-4888 www.insul-8.com

FESTOON SYSTEMS are a clean, economical and efficient method of managing power andcontrol cables for mobile equipment.

FESTOON SYSTEMS are generally used on overhead cranes for the transmission of power andcontrol signals for crossbridge trolley travel, but they can also be applied to crane runway travel. Other applications for festoon systems are transfer cars, monorails, refuse cranes,waste water treatment machines and other material handling applications.

INSUL-8 CORPORATION offers a comprehensive line of festoon products, ranging from simplest of systems running on stretched wire rope to the complex, high speed demands of por-tal and container cranes. Insul-8’s festoon systems run on wire rope, c-track, square bar andI-Beams, with trolleys able to support static loads up to 175 pounds and up to 1,100 poundswith Heavy-Duty festoon systems. Insul-8 festoon systems are designed to support and protectflat and round electrical cables and air or water hoses throughout the travel of the equipment.Our systems can operate in indoor and outdoor environments and can also be designed forharsh, aggressive environments.

ABOUT OUR SYSTEMS

CABLE AND CONNECTORS

STRETCHED WIRE ROPE SYSTEMS LOAD 40 LBS SPEED: 200 FPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4C-TRACK SYSTEMS

Standard Duty LOAD: 40 LBS SPEED: 250 FPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6Standard Duty Pre-assembled Festoon Kits LOAD: 40 LBS SPEED: 250 FPM . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21Heavy Duty LOAD LOAD: 80 LBS SPEED: 500 FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Flat Cable and Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Insul-8 also offers a full range of round cable and hose to meet your requirements

SQUARE BAR SYSTEMS

Standard Duty LOAD: 45 LBS SPEED: 250 FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Heavy Duty LOAD: 175 LBS SPEED: 250 FPM

Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Flat Cable Trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Round Cable Trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

I-BEAM SYSTEMSSeries 200 LOAD: 55LBS SPEED: 200 FPM

Series 250 LOAD: 95 LBS SPEED: 250 FPM



FESTOON ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19PUSH BUTTON PENDANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19FESTOON KITS LOAD: 40 LBS SPEED: 250 FPM . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 21PRE-ASSEMBLY (LEARN MORE ABOUT IT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

IF YOU DON’T SEE WHAT YOU’RE LOOKING FOR, PLEASE ASK US.Insul-8 also provides customized systems for unique applications including Heavy Duty Festoon systems.

Flat Cable Trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Flat Cable Trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Flat Cable Trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Round Cable Trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Flat Cable Trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Round Cable Trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 18


FLAT CABLE AND CONNECTORS

* See Current Correction Factors for Temperatures above 300C (860F)** For Crane and hoist motors in accordance with article 610 of the 1989 National Electric Code for 900C Cables✝ Unshielded cable measurements may vary due to manufacturing tolerances. Contact Insul-8 for shielded cable dimensions.✝✝ All cables from #10 AWG through #16 AWG have rip cords for easy removal of the outer jacket.

Flat CableRequired cable length equals track plus 10% plus length required for end connections

Flat Cable ConnectorsFor Termination of Cable at Power Source or Junction Box.

Construction: Aluminum Body / Rubber Bushing

Heat shrinkable connections for single cable and multiple cable groups, for flat and round cable.

Corrosion Resistant ◆ Flame Retardant Exceeds navy requirements for tightness and integrity when used with

one flat cable or multiple flat cables of the same size

Dim “A”

Cable Part Number Cable Size

YellowPVC

Jacket

23958Y

26550Y

21814Y

26698Y

22542Y

22994Y

21815Y

26005Y

26110Y

22607Y21813Y

23324Y

ShieldedFlat

Cable

31772

31580

31734

Numberof

Conductors

44

4

4

4

4

4

8

8

8

12

124

AWGWireSize

#2

#4#6

#8

#10

#12

#14

#12

#14

#16

#14

#16#16

ContinuousDuty Rating

at 300C (86

0F)

Ambient Amps*

120

90

70

50

40

30

25

21

17

15

17

15

Short Time Rating Amps**

60 Min. 30 Min.

148 173

111 130

83 94

63 6949 52

36 40

31 32

No. ofStrands perConductor

665

420266

168

105

65

41

6541

65

41

6565

Weight perFoot (lbs)

1.27

.75

.60

.42

.24

.16

.12

.32

.22

.18

.34

.27

.16

Nominal DimensionsUnshielded Cable

(Inches)=

.56” x 1.96”

.49” x 1.70”

.44” x 1.45”

.37” x 1.19”

.27” x .88”

.23” x .71”

.21” x .63”

.23” x 1.34”

.21” x 1.18”

.20” x 1.11”

.21” x 1.90”

.20” x 1.61”.24” x .76”

Control Cables

No ShortTime Rating

No. of Cond

444444888

1212888

Wire Size (AWG)

#4#6#8

#10#12#14#12#14#16#14#16#12#14#16

Cable SizeNPT

2”2”

1.5”1”1”1”

1.5”1.5”1.5”2”2”2”

1.5”1.5”

RefCable #

26550Y21814Y26698Y22542Y

22994Y21815Y26005Y26110Y22607Y21813Y23324Y26005Y26110Y22607Y

CatalogNumber

3583835838B3583735835C35835B3583535837B35837C35837D35838C35838D35838G35837E35837F

No. of Cables

11111111111222

3

No. of Cond

121284848484

8484

Wire Size (AWG)

#14#16

#16#14#14#14#16#10#14#10#16#12#14#12

Cable SizeNPT

2”2”

1.5”

1.5”

1.5”

1.5”

1.5”

1.5”

RefCable # 21813Y

23324Y22607Y21815Y26110Y21815Y22607Y22542Y26110Y22542Y

22607Y22994Y26110Y22994Y

CatalogNumber

35838E35838F

35837G

35837K

35837J

35837H

35837L

35837M

No. of Cables

22

11111111

2

2

CatalogNumber

031470314603145

CableOpening

1.60”1.10”.75”

KnockoutDiameter

2.00”1.37”1.00”

Dimension“A”

6.17’4.5”

4.09”

Weightlbs..40.10.06

Ph: 402-339-9300/800-521-4888 www.insul-8.com


STRETCHED WIRE FESTOON KITS

Stretched Wire Rope Festoon Systems are well suited for light duty applications where an intermediate supportstructure is not available. Economical and dependable, stretched wire rope systems provide electrification tosmall cranes, moving hoists and jib cranes.

SW2

SW6

SW2 SW

6SW10

SW8

SW9

SW7

SW1

SW3

SW11

SW12

SW13

SW5

SW15

SW4

SW1

SW3

SW14

2486224863248642486524866

2486724868248692487024871

Max. Span(In Feet)

20406080100

No. ofTrolleysin Kit

3691317

FOR FLAT CABLE:

FOR HOSE & ROUND CABLE:

SW2

SW5

SW4

SW3

SW1

Catalog #

22950

23288

22830

22828

22825

22826

Component

Nylon Coated Wire Rope, 1/4” dia.

Hardware Kit

Tow Bar

Tow Trolley (2 wheel)

Trolley (1 wheel)

Trolley (2 wheel)

SW14

SW15

SW6

Catalog #

22836

22834

22835

Component

Anchor Bracket

Flat Cable Saddle < 3/4” (20mm) wide

Flat Cable Clip

SW2

SW7

SW6

SW3

SW1

Catalog #

22950

23288

22830

22836

22829

Component

Nylon Coated Wire Rope 1/4” Dia.

Hardware Kit

Tow Bar

Anchor Bracket

Tow Trolley (2 wheel)

SW9

SW12

SW11

SW10

SW8

Catalog #

22825

22827

25689

22831

22832

Component

Trolley (1 wheel) *not shown

Trolley (2wheel) shown

Adapter

Cable Clip ( 3/16” to 3/8” )

Cable Clip ( 3/8” to 9/16” )

4Ph: 402-339-9300/800-521-4888 www.insul-8.com

LOAD: 10 LBS (1 WHEEL) MAX. SPEED: 200 FPM MAX.LOAD: 20 LBS (2 WHEEL) MAX. SPEED: 200 FPM MAX.

LOAD: 10 LBS (1 WHEEL) MAX. SPEED: 200 FPM MAX.20 LBS (2 WHEEL) MAX. SPEED: 200 FPM MAX.

Kits include all components listed below:

Kit Part NumberMax. Cable Width

Single Wheel Double Wheel3/4” Max. 1-3/4” Max.

*1 wheel

2487224873248742487524876

2 wheel

2488724888248892489024891

*1 wheel

2487724878248792488024881

2 wheel

2489224893248942489524896

*1 wheel

2488224883248842488524886

2 wheel

2489724898248992490024901

Kit Part NumberCable / Hose O.D.

3/16” - 3/8” Max. 3/8” - 9/16” Max. 9/16” - 3/4” Max.

Max Span(In Feet)

No. ofTrolleysin Kit

20406080100

3691317

SW13

Catalog #

22833

Component

Cable Clip (9/16” to 3/4”)


STANDARD DUTY C-TRACK SYSTEM COMPONENTS

14 Gauge Galvanized Steel ◆ Stainless Steel

Catalog Number

GalvanizedSteel

StainlessSteel

WeightPounds Description

14 Gauge C-Track10 ft. Section20 ft. SectionCross Arm Support Bracket:36678 = 12 Gauge 36679 = 14 Gauge

Track Joint AssemblyOne required for each track section per runless one.

Joint clamp for secure attachment and proper align-ment of track sections. Includes four bolts, lock wash-ers and nuts.

Welded Joint Assembly for joining track section.

Track Hanger Clamp AssemblyOne required for each cross arm supportbracket for each track run. 5’ spacing.Designed to be mounted on angle iron brackets with one mounting hole.For mounting track to Cross Arm Support Bracket.Includes all required hardware. (Not Shown) Low profile track hanger assembly for mounting trackto cross arm support. (Not Shown)

End StopOne required for power system, two required for control systems with control trolley.

Beam Clamp for Cross ArmSupportTwo required for each cross arm support bracket.

End ClampOne required for each track run at storageend of track.

2.75” Dia. Steel saddle with clamp and hardware to secure cable.

2” Dia. Plastic saddle with clamp to secure cable.Black anodized aluminum saddle and stainless steel hardware.

.75

.75

.40

.51

.81

.20

.38

.56

.42

.56

2772527724

27726

32059

28741

27727

27728

2220921909

3667836679

21954

31856

2851035707

22005

23381

22264

2195728616

2851135706

28742 .40.40

Anchor ClampOne required per track runDesigned to hold track in place.For use with Cross Arm Support Bracket. Includes all required hardware. (Not Shown)

Standard Duty “C” Track festoon systems are light duty systems suited for cranes and hoists usually with a lighter duty cycle.Available for power or control systems in both straight and curved track configurations. Trolleys available in polypropylenegalvanized steel and aluminum.

5

from 12” to 48” in 6”increments (please specify)

Ph: 402-339-9300/800-521-4888 www.insul-8.com

1020

2lbs/ft1lb/ft

Load: 40 lbs max.Speed: 250 fpm max.

✱

Plastic trolleys, tow trolleys and end clamp suitable for use on galvanized steel systems are noted with “✱”


STANDARD DUTY C-TRACK SYSTEM COMPONENTS

Catalog NumberGalvanized

SteelStainless

SteelWeightPounds Description

Tow BarOne required for each tow trolley.

For mounting on moving equipment 16” long.

Control Box TrolleyTwo trolleys and one steel saddle mounted onbracket plus fittings to attach control box.(Control box not included.)Same as 22203 except with stainless steel trolleysand stainless steel wheels and hardware.

Junction Boxes and Terminal Strips8” x 10” x 4” steel junction box NEMA 13

8” x 10” x 4” steel junction box for control box trolley. Complete with 12 pole terminal strip.Galvanized Steel Rated at: NEMA 13Stainless Steel Rated at: NEMA 4X

12-pole terminal strip.

Cable Trolley - 5”Load rating 40 lbs max.

5-inch trolley with 4 steel shielded ball bearingwheels, 2.75” Dia. steel saddle and hardware.

Black anodized aluminum body and trolley with stainless steel wheels and hardware.

Cable Trolley - 3”3 inch steel trolley with 4 shielded steel ball bearing wheels, 2.75” Dia. steel saddle and hardware.

3 inch plastic trolley with 4 shielded steel ball bear-ing wheels, 2” Dia plastic saddle. (not shown)

Black anodized aluminum body and saddle with stainless steel wheels and hardware.

1.2

2.75

3.0

9.0

9.0

.20

1.0

.89

.70

.40

.70

32166

28314K

32062

32061

22830

22203B

28315

28314

34876

21941

21991

28615

Tow Trolley Load rating: 40 lb max.

One required for each piece of moving equip-ment to be electrified.

Plated steel trolley with 2.75” Dia. saddle with cut outfor tow bar.

Plastic trolley with 2” Dia. plastic saddle with cut outfor tow bar.Black anodized aluminum tow trolley with 4 stainlesssteel wheels and hardware.

1.12

.70

1.1232060

22168

28614

2366(16 Pin)

2367(24 Pin)

5.28

5.59

Control Unit Trolley with Quick DisconnectLead trolley in control festoon system. Manually pulled with push-button pendant attached to drop cable. Drop cable is then wired into lower half of “quick disconnect”. Flat festoon cable is wired into upper half of “quick disconnect”. Zinc plated steel trolleys and hardware.

Electrical Ratings: 16A Max. 600 Volts AC

6Ph: 402-339-9300/800-521-4888 www.insul-8.com

14 Gauge Galvanized Steel ◆ Stainless Steel (Continued)


✱

✱


HEAVY DUTY C-TRACK SYSTEM COMPONENTS

12 Gauge Galvanized Steel ◆ Flat Cable Components

Catalog Number WeightPounds Description

12 Gauge C-Track10 ft. Section

20 ft. Section

Track Joint AssemblyOne required for each track section per run less one.Joint clamp for secure attachment and proper alignment of track sections. Includes four bolts, lock washers and nuts.

End StopOne required for Power System, two required for Systems with Control Trolley.

Anchor ClampOne required per track run.Designed to hold track in place.

End Clamp One required for each track run at storageend of track.Aluminum saddle 4” dia. with clamp and hardware to secure cable 5 1/4” wide.

20.040.0

1.08

.45

.20

1.63

2221021805

21806

28513

28508

21932

28512 .45

Track Hanger Clamp AssemblyOne required for each angle iron bracketfor each track run. 10’ spacing.Designed to be mounted on angle ironbrackets with one mounting hole.

Cable Trolley

Trolley load rating 80 lbs max.8” high strength aluminum body with 4” diaaluminum saddle. Trolley bumpers.

3.021802

Heavy Duty “C” Track festoon systems are suited for cranes and hoists usually with a heavier duty cycle.Available for power or control systems in straight configurations. Trolleys available heavy gauge aluminum withaluminum saddle only.

7 Ph: 402-339-9300/800-521-4888 www.insul-8.com



HEAVY DUTY C-TRACK SYSTEM COMPONENTS


Tow BarOne required for each tow trolley.For mounting on moving equipment 24” long.

Control Box TrolleyTwo trolleys and one aluminum saddle 4” dia.mounted on bracket plus fittings to attach controlbox.(Junction Box sold separately below.)

Junction Boxes and TerminalStrips8” x 10” x 4” Steel junction box. NEMA 13

8” x 10” x 4” steel junction box for control box trolley. Complete with 12 pole terminal strip.

12-pole terminal strip.

2.63

12.5

9.0

9.0.20

22008

22350

28315

2831434876

Tow Trolley Load rating: 80 lb max.One required for each piece of movingequipment to be electrified.

8” trolley and aluminum saddle 4” dia. with cut outfor tow bar.4.7522169

Trolleys, saddles and all associated parts for round cable and air hose systems are available. Refer to the Installation Operation and Maintenance manual (I.O.M.) and Festoon Price List for details.

I.O.M. Price List

An I.O.M. is included with each order. Price lists may be obtained through your local rep.

8Ph: 402-339-9300/800-521-4888 www.insul-8.com

12 Gauge Galvanized Steel ◆ Flat Cable Components

Continued



STANDARD DUTY SQUARE BAR COMPONENTS

Catalog Number

Standard Stainless SteelWeightPounds Description

Track (Square Bar)20 ft. Section, H.R. Steel Track

20 ft. Section, Stainless Steel Track

20 ft. Section, Galvanized Steel Track

Track Joint

Track joint for secure attachment and proper alignment of track sections.

End Stop

Designed to be located between end clamp andintermediate trolley.

End Clamp

One required per system at storage end of track.

28.028.028.0

.25

.75

1.50

24525

3460127843

25681 27845

25596 27847

25595 28548

25598 27846 .50

Track Hanger Designed to be mounted on angle iron bracket. 5’ spacing. Typical, 2’-6” spacing in storage area.

NOTE: Use Drill Fixture for Drilling Holes.Part #: 25728

Cable Trolley

Trolley load rating 45 lbs max.4” long body with 2.75” dia. aluminum saddle

Tow Trolley

Load rating 45 lbs max. One required per system.4” long body with cut out for Tow Bar.

2.5

3.0

25593

25594

28622

28621

Curved Systems and Control Trolleys also available.

9 Ph: 402-339-9300/800-521-4888 www.insul-8.com


Junction Boxes and Terminal Strips8” x 10” x 4” steel junction box NEMA 13.(Terminial Strip not included)8” x 10” x 4” steel junction box for control boxtrolley. (Includes 12 pole terminal strip.)Galvanized Steel Rated at: NEMA 13Stainless Steel Rated at: NEMA 4X12-pole terminal strip.

9.09.0

.20

28314K

28315

28314

34876


HEAVY DUTY SQUARE BAR COMPONENTS

Catalog Number

Standard Stainless Steel WeightPounds Description

Track (Heavy Square Bar)20 ft. Section, H.R. Steel Track

20 ft. Section, Stainless Steel Track

20 ft. Section, Galvanized Steel Track

Track Joint

Track joint for secure attachment and proper alignment of track sections.

Drill Fixture

Used for drilling holes at proper position for attachment of hangers, end clamps and end stops.

46.046.046.0

.50

2.0

26.0

24526

3460327663

25683 27664

25670

25726

Special Unit.Available

upon request.

25667 27671 1.50

Track Hanger

Designed to be mounted on angle iron bracket.10’ spacing. Typical 5’ spacing in storage area.

Curved Systems also available.

Curved festoon systems may be required for electrification and/or control of curved monorails and machines that travel in a circular motion. Also, some systems may require more storage space than available.

Additional storage space may be gained by curving the festoon track 900 to the crane rail.

Consult Insul-8 for details on curved systems and other solutions for your festoon application.

25726

Control Box Trolley

Two trolleys and one aluminum saddle 4” dia. mounted on bracket plus fittings to attach controlbox.(Control box not included.)

Junction Boxes and TerminalStrips8” x 10” x 4” steel junction box NEMA 13.(Terminial Strip not included)8” x 10” x 4” steel junction box for control boxtrolley. (Includes 12 pole terminal strip.)Galvanized Steel Rated at: NEMA 13Stainless Steel Rated at: NEMA 4X12-pole terminal strip.

9.0

9.0

.20

28314K

28315

28314

34876

10Ph: 402-339-9300/800-521-4888 www.insul-8.com



HEAVY DUTY SQUARE BAR TROLLEYS FOR FLAT CABLE

Heavy Duty Square Bar Trolleys feature all-steel body construction with aluminum cable saddle. Thetrolleys are suitable for indoor and outdoor applications for flat cable. Standard wheels are steelwith sealed ball bearings.

Catalog Number

Weight in Pounds

Description One Tow Trolley required per system.Supplied with towing box for tow bar.

Standard construction consists of steelbody, aluminum saddle. Maximum loadper trolley is 95 lbs.

One End Clamp required per system.Bolted to Square Bar Track.

13.5 11.5 8.5

See Chart Below See Chart Below See Chart Below

*S1 *S1 *S1

Tow Trolley Cable Trolley End Clamp

Body: Steel-Zinc PlatedSaddle: AluminumWheels: 1.77” O.D.Hardware: Zinc Plated

Cable Pad: Neoprene RubberLoad: 175 lbsW2= Max Cable Window WidthS1= Max Cable Window Height

Specifications & Dimensions

Insul-8 also offers Stainless Steel Trolleys. Please contact the factory if you are interested in these units.

11

Tow Trolley Cable Trolley End Clamp Dimensions (Inches)Catalog #4540045400B4540145401B4540245402B4540645406B4540745407B4541045410B

Length11.12511.12512.62512.62515.12515.12512.62512.62515.12515.12515.12515.125

Catalog #4542645426B4542745427B4542845428B4543245432B4543345433B4543645436B

Length8.6258.625

10.12510.12512.62512.62510.12510.12512.62512.62512.62512.625

Catalog #4545345453B4545445454B4545545455B4545945459B4546045460B4546345463B

Length7.3757.3758.8758.875

11.37511.3758.8758.875

11.37511.37511.37511.375

Saddle Dia.444444666688

Width5.25

85.25

85.25

85.25

85.25

85.25

8

W23.96.73.96.73.96.73.96.73.96.73.96.7

*S122

3.53.56622

4.54.522

Ph: 402-339-9300/800-521-4888 www.insul-8.com

Load: 175 lbs max.

Speed: 250 fpm max.


HEAVY DUTY SQUARE BAR TROLLEYS FOR ROUND CABLE

Heavy Duty Square Bar Trolleys feature all-steel body construction with aluminum cable saddle. Thetrolleys are suitable for indoor and outdoor applications for round cable. Standard wheels are steel,with sealed ball bearings.

Catalog Number

Weight in Pounds


Standard construction consists of steelbody, aluminum saddle. Maximum loadper trolley is 95 lbs.

One End Clamp required per system.Bolted to Square Bar Track.

14.0 12.0 9.0


*S1 *S1*S1

Tow Trolley Trolley End Clamp

Body: Steel-Zinc PlatedSaddle: AluminumWheels: 1.77” O.D.Hardware: Zinc Plated

Cable Pad: Neoprene RubberLoad: 175 lbsW2= Max Cable Window WidthS1= Max Cable Window Height


Insul-8 also offers Stainless Steel Trolleys. Please contact the factory if you are interested in these units.

Tow Trolley Cable Trolley End Clamp Dimensions (Inches)Catalog #4540345403B4540845408B4541145411B

Length11.12511.12512.62512.62515.12515.125

Catalog #4542945429B4543445434B4543745437B

Length8.6258.625

10.12510.12512.62512.625

Catalog #4545645456B4546145461B4546445464B

Length7.3757.3758.8758.875

11.37511.375

Saddle Dia.446688

Width5.25

85.25

85.25

8

W23.96.73.96.73.96.7

*S1.4”.4”.6”.6”.8”.8”

12Ph: 402-339-9300/800-521-4888 www.insul-8.com

Load: 175 lbs max.

Speed: 250 fpm max.


SERIES 200 I BEAM FOR FLAT CABLE

This I-Beam festoon system is ideal for slow speed operation at speeds up to but not exceeding 200fpm with loads of up to 55lbs. The Series 200 “I” Beam System can be strategically used indoorswhere festoon cable systems are required to operate on an “I” Beam. These “I” Beam trolleys aresand cast aluminum with nylon wheels.

Catalog Number

Weight in Pounds


Standard construction consists of 5” longbody, 2.75”Dia. x 4” wide saddle.Maximum load per trolley is 55 lbs.

One End Clamp required persystem. Bolted to “I” Beam with(2) 1/4-20 x .25” mounting bolts.

2.75 2.0 .75

24829 24830 24828


Body: Sand cast AluminumSaddle: 2.75” Dia. AluminumWheels: NylonCable Pad: Neoprene Rubber

Load: 55 lbs. maxSpeed: 200 fpm. maxMaximum “I” Beam Flange Width: 4.50”


13

● Trolleys available for “I” Beam flange width up to 6.25”

● Trolleys with steel wheels available, simply order: 28904 / 2.0 lbs Tow Trolley33530 / 2.75 lbs Cable Trolley 24828 / .75 lbs End Clamp

“I” Beam (customer provided)

CableTrolley

TowWebbing

FestoonCable

TowTrolleyEnd

Clamp(Fixed)

CablePigtail

forHookup

Ph: 402-339-9300/800-521-4888 www.insul-8.com

Load: 55 lbs max.

Speed: 200 fpm max.

For trolleys without anti-kick rollers simplyadd “B” to the end of the part numer.

NOTE:



Series 250 “I” Beam Trolleys feature all-steel body construction with aluminum cable saddles. Thesetrolleys are suitable for indoor and outdoor applications for flat cable. Wheels are available in steelfor standard applications and bronze for spark resistant environments.

Catalog Number

Weight in Pounds

DescriptionOne Tow Trolley required per system.Supplied with towing box for tow bar.Running Gear with Anti-Lift rollersrequired.

Standard construction consists of steelbody, aluminum saddle. Maximum loadper trolley is 95 lbs. Running gear with or without Anti-Lift rollers available.

One End Clamp required per system.Bolted to “I” Beam.

14.5 10.0 8.0


*S1 *S1 *S1


Running Gear: W-BeamsWithout Anti-Lift Rollers: 45197

With Anti-Lift Rollers: 45198

Running Gear: S-BeamsWithout Anti-Lift Rollers: 45187


(Consult factory for bronze rollers and other beam sizes!)

Body: Steel-Zinc PlatedSaddle: AluminumWheels: 40mm Steel FlangedAnti-Lift Bearing: 1.38 Dia.

SteelHardware: Zinc PlatedCable Pad: Neoprene RubberLoad: 95 lbsW2= Max Cable Window WidthS1= Max Cable Window Height


BeamW4 x 13W5 x 16W5 x 19

CodeA

BC

BeamW6 x 9

W6 x 12W8 x 10

CodeDEK

Beam

S4 x 7.7S4 x 9.5S5 x 10.0

CodeCDE

Beam

S6 x 12.5S6 x 17.25S7 x 15.3

Code

GHJ

Tow Trolley Trolley End Clamp Dimensions (Inches)Catalog #4510045100B4510145101B4510245102B4510645106B4510745107B4511045110B

Length11.12511.12512.62512.62515.12515.12512.62512.62515.12515.12515.12515.125

Catalog #4512645126B4512745127B4512845128B4513245132B4513345133B4513645136B

Length8.6258.625

10.12510.12512.62512.62510.12510.12512.62512.62512.62512.625

Catalog #4515345153B4515445154B4515545155B4515945159B4516045160B4516345163B

Length7.3757.3758.8758.875

11.37511.3758.8758.875

11.37511.37511.37511.375

Saddle Dia.444444666688

Width5.25

85.25

85.25

85.25

85.25

85.25

8

W23.96.73.96.73.96.73.96.73.96.73.96.7

*S122

3.53.56622

4.54.522

14Ph: 402-339-9300/800-521-4888 www.insul-8.com

Load: 95 lbs max.

Speed: 250 fpm max.

✱

✱


SERIES 250 I BEAM FOR ROUND CABLE

Series 250 “I” Beam Trolleys feature all-steel body construction with aluminum cable saddles. Thesetrolleys are suitable for indoor and outdoor applications for round cable. Wheels are available insteel for standard applications and bronze for spark resistant environments.

Catalog Number

Weight in Pounds


Standard construction consists of steelbody, aluminum saddle. Maximum loadper trolley is 95 lbs. Running gear with or without Anti-Lift rollers available.


15.0 10.5 8.5


S1 S1 S1






(Consult factory for bronze rollers and other beam sizes!)

Body: Steel-Zinc PlatedSaddle: AluminumWheels: 40mm Steel FlangedAnti-Lift Bearing: 1.38 Dia.




CodeA

BC

BeamW6 x 9

W6 x 12W8 x 10

CodeDEK

Beam

S4 x 7.7S4 x 9.5S5 x 10.0

Code

CDE

Beam

S6 x 12.5S6 x 17.25S7 x 15.3

Code

GHJ


Length11.12511.12512.62512.62515.12515.125

Catalog #4512945129B4513445134B4513745137B

Length8.6258.625

10.12510.12512.62512.625

Catalog #4515645156B4516145161B4516445164B

Length7.3757.3758.8758.875

11.37511.375

Saddle Dia.446688

Width5.25

85.25

85.25

8

W23.96.73.96.73.96.7

S1.4.4.6.6.8.8

15 Ph: 402-339-9300/800-521-4888 www.insul-8.com

Load: 95 lbs max.

Speed: 250 fpm max.

✱

✱



The economical Series 300 “I” Beam Trolleys for flat cable are designed to run on S3 x 5.7#, S3 x7.5# or S4 x 7.7# “I” beams only. The saddle is suspended from the trolley by a pivot mechanismwhich allows the cable package to sway during crane operation providing smoother operation. Lead trolleys are supplied with anti-lift rollers as standard.


Tow TrolleyOne required per system. Complete with Anti-LiftRollers positioned as Lead Trolley in system isequipped with cut out box for engagement of towbar from mobile consumer.

Length= 8.00”

Cable TrolleyStandard construction consists of steel body, steelsaddle. Maximum load per trolley is 150 lbs.

Length= 5.50”

End ClampOne End Clamp required per system. Positioned atend of system and clamped to “I” Beam.

Length= 7.77”

Control Box TrolleyTwo trolleys and one steel saddle mounted on bracket plus fittings to attach control boxJunction Box sold separately (See Page 10.)

Length = 26.25”

Single Control TrolleySingle trolley suitable for mounting junction box.

Length = 5.5”

9.0

5.0

5.0

13.0

5.0

34366

34364

34365

34925

34407

Body: Low Carbon SteelSaddle: Low Carbon SteelFinish: Zinc Plated w/yellow Dichromate SealHardware: Zinc Plated

Rollers:● Main - 1.68” Dia. Hardened Steel● Anti-Lift - 1.19” Dia. Hardened Steel.

Saddle Diameter: 3.4”Cable Window: 2.38” wide x 1.00” high

Specifications

16Ph: 402-339-9300/800-521-4888 www.insul-8.com




Series 350 “I” Beam Systems are designed for flat cable in a wide range of applications such as steel mills and aluminumsmelters. These trolleys are built to meet the demanding requirements of large cranes and moving machinery. The trolleysare provided with side guide and anti-lift rollers to withstand the most demanding applications. The trolleys are suitable forindoor and outdoor applications for flat cable. Wheels are available in steel for standard applications.

Catalog Number

Weight in Pounds


Standard construction consists of steelbody, aluminum saddle. Maximum loadper trolley is 175 lbs. Running gear withor without Anti-Lift rollers available.


16.5 12.0 10.0


*S1 *S1 *S1






Need another beam size? Call us.

Body: Steel-Zinc PlatedSaddle: AluminumWheels: 2” Dia. Crowned SteelAnti-Lift Bearing: 1.38 Dia.

SteelHardware: Zinc PlatedCable Pad: Neoprene RubberLoad: 175 lbs Max.W2= Max Cable Window WidthS1= Max Cable Window Height



CodeABC

BeamW6 x 9

W6 x 12W8 x 10

CodeDEK

Beam

S4 x 7.7S4 x 9.5S5 x 10.0

Code

CDE

Beam

S6 x 12.5S6 x 17.25S7 x 15.3

CodeGHJ

Tow Trolley Trolley End Clamp Dimensions (Inches)Catalog #4510045100B4510145101B4510245102B4510645106B4510745107B4511045110B

Length11.12511.12512.62512.62515.12515.12512.62512.62515.12515.12515.12515.125

Catalog #4512645126B4512745127B4512845128B4513245132B4513345133B4513645136B

Length8.6258.625

10.12510.12512.62512.62510.12510.12512.62512.62512.62512.625

Catalog #4515345153B4515445154B4515545155B4515945159B4516045160B4516345163B

Length7.3757.3758.8758.875

11.37511.3758.8758.875

11.37511.37511.37511.375

Saddle Dia.444444666688

Width5.25

85.25

85.25

85.25

85.25

85.25

8

W23.96.73.96.73.96.73.96.73.96.73.96.7

*S122

3.53.56622

4.54.522

17 Ph: 402-339-9300/800-521-4888 www.insul-8.com

Load: 175 lbs max.

Speed: 350 fpm max.

MOTIV-8TM

FESTOONING SYSTEMS FROM INSUL-8

SERIES 350 I BEAM FOR ROUND CABLE

Series 350 “I” Beam Systems are designed for round cable in a wide range of applications such as steel mills and aluminum smelters. These trolleys are built to meet the demanding requirements of large cranes and moving machinery.These trolleys are provided with side guide and anti-lift rollers to withstand the most demanding applications. Trolleys aresuitable for indoor and outdoor applications for round cable. Wheels are available in steel for standard applications.

Catalog Number

Weight in Pounds


Standard construction consists of steelbody, aluminum saddle. Maximum loadper trolley is 175 lbs. Running gear withor without Anti-Lift rollers available.


17.0 13.0 11.0


*S1 *S1 *S1






(Consult factory for other beam sizes!)

Body: Steel-Zinc PlatedSaddle: AluminumWheels: 2” Dia. (40mm) Steel FlangedAnti-Lift Bearing: 1.38 Dia.




CodeABC

BeamW6 x 9

W6 x 12W8 x 10

CodeDEK

Beam

S4 x 7.7S4 x 9.5S5 x 10.0

Code

CDE

Beam

S6 x 12.5S6 x 17.25S7 x 15.3

CodeGHJ


Length11.12511.12512.62512.62515.12515.125

Catalog #4512945129B4513445134B4513745137B

Length8.6258.625

10.12510.12512.62512.625

Catalog #4515645156B4516145161B4516445164B

Length7.3757.3758.8758.875

11.375.11.375

Saddle Dia.446688

Width5.25

85.25

85.25

8

W23.96.73.96.73.96.7

*S1.4.4.6.6.8.8

18Ph: 402-339-9300/800-521-4888 www.insul-8.com

Load: 175 lbs max.

Speed: 350 fpm max.


FESTOON ACCESSORIES

CatalogNumber Length Nominal

Weight (lbs) Description

Tow CableOptional item used in both High Speed and Outdoorapplications.

Designed for use on:● Heavy Duty C-Track● Heavy Duty Square Bar ● 250 Series “I” Beam● 350 Series “I” Beam

Tow WebbingOptional item used in both High Speed and Outdoorapplications ideal for systems in spark resistant envi-ronments. Ordered by the foot.

Designed for use on:● Standard Duty C-Track● Standard Duty Square Bar ● 200 Series “I” Beam ● 300 Series “I” Beam

Flat Cable OrganizerOptional item for systems in order to prevent flatcables within the loops from becoming tangled orcaught during operation.

Designed for use on:● 200 Series “I” Beam● 250 Series “I” Beam● 300 Series “I” Beam● 350 Series “I” Beam● Can also be used on other festoon systems

depending upon application.

Round Cable OrganizerOptional item for systems in order to prevent roundcables within loops from becoming tangled or caughtduring operation. Either one or two per loop may berequired.

Designed for use on:● 200 Series “I” Beam● 250 Series “I” Beam● 300 Series “I” Beam● 350 Series “I” Beam● Can also be used on other festoon systems

depending upon application.

.28

.40

.51

.63

.74

.85

.18 lbs/ft

2469024690B24690C24690D24690E24690F

03159

4’-6’6’-8’8’-10’10’-12’12’-14’14’-16’

AsRequired

TW

WH1

H2

CatalogNumber40619J40619K

H1&H24.5”4.5”

W5.1”6.7”

TW7.8”

10.6”

Dimensions: Inches

L1

W

D

L2 CatalogNumber

40600P40600Q

“D” CableDia. RangeUp to .80Up to .80

L16.0”8.8”

L23.9”6.7”

Wt(lbs.)

.751.1

19 Ph: 402-339-9300/800-521-4888 www.insul-8.com

Push button pendants are used in conjunction with conductor bar, festoon systems orreels as a “point of control” stations for overhead cranes, hoists and conveyors. Insul-8 offers a complete line of push button pendants.

Please consult Insul-8, your local rep or request catalog: PEN001 for further information.

INSUL-8 offers a complete selection of accessories for your festoon system, including a variety of push-button pendants to maximize the value of your system.


C-TRACK FESTOON KITS

20

FOR POWER SYSTEMS

Fixed EndPigtail

Trolley

Track

EndStop

FlatCable

EndClamp

HangerClamp

FIXED END

PIGTAIL

LoopDepth

20’3667118.381.3538

30’36671B

27.841.8945

40’36671C

37.312.4370

50’36671D

46.772.9777

60’36671E

56.53.24102

Crane SpanSystem Part NumberActive Travel (feet)Storage Distance (feet)Weight (lbs)

14 & 16 AWG - 12 Conductor Systems (#14-4C, #16-8C)

Pre-configured, standard duty C-Track festoon system kits provide a simple method for order-ing complete crossbridge power systems for crane applications. If you need a kit with other cable combinationsand trolley styles, just ask us. Kits can also be ordered pre-assembled by simply adding the letter “P” to the endof the system part number. See page 22. Example: 36670E = 60’ power system

36670EP = 60’ pre-assembled power system

20’3667018.381.3538

30’36670B

27.841.8945

40’36670C

37.312.4370

50’36670D

46.772.9777

60’36670E

56.53.24102


14 & 16 AWG - 12 Conductor Systems (#14-4C, #16-8C)

Ph: 402-339-9300/800-521-4888 www.insul-8.com

KITS INCLUDE THE FOLLOWING: c-track, splices, hangers, anchor hangers, trolleys, tow trolley, end clamp,end stop, flat cable and connectors. Systems are calculated based on a 3 ft loop depth. Cable lengthsupplied includes 10 additional feet of termination purposes. Hanger supports are based on five footcenters.

C-Track festoon kit using plastic trolley #28615

C-Track festoon kit using steel trolley #21991


C-TRACK FESTOON KITS

21

FOR CONTROL SYSTEMS

12.01Trolley

PendantTrolley

DripLoop

Track

EndStop

FlatCable

EndClamp

Fixed EndPigtail

LoopDepth

20’3667317.082.7943

30’36673B

26.813.0660

40’36673C

36.273.6076

50’36673D

45.734.1493

60’36673E55.194.68109


16 AWG - 16 Conductor Systems (2x#16-8C)

Pre-configured standard duty C-Track festoon system kits provide a simple method for order-ing complete crossbridge control systems for crane applications. If you need a kitwith other cable combina-tions and trolley styles, just ask us. Push-button pendant and drop cable are to be ordered separately. Kits canalso be ordered pre-assembled, by simply adding the letter “P” to the end of the system part number. Seepage 22. Example: 36672 = 20’ control system

36672P = 20’ preassembled control system


16 AWG - 16 Conductor Systems (2x#16-8C)

20’3667217.082.7943

30’36672B

26.813.0660

40’36672C

36.273.6076

50’36672D

45.734.1493

60’36672E55.194.68109

Ph: 402-339-9300/800-521-4888 www.insul-8.com

KITS INCLUDE THE FOLLOWING: c-track, splices, hangers, anchor hangers, trolleys, 16 pin control trolleywith quick disconnect, end clamp, end stops, flat cable and connectors. Systems are calculated basedon a 3 ft loop depth. Cable length supplied includes 5 additional feet of termination purposes. Hangersupports are based on five foot centers.

C-track festoon kit using plastic trolley #28615

C-track festoon kit using steel trolley #21991


FESTOON PRE-ASSEMBLY

22

WHY SHOULD YOU CONSIDER HAVING YOUR

NEXT FESTOON SYSTEM ARRIVE PRE-ASSEMBLED?

Insul-8 offers complete pre-assembled festoon systems. Systems are carefully assembled by experienced personnel working under ideal conditions.Pre-assembly reduces potential field problems Reduces installation time and related expenses.Systems are assembled and shipped on a steel shipping frame or in a cardboard container designed for safe and easy transfer to the main system track.

Please contact Insul-8 for more details.

Above: Typical control system shipped in box.Note that control trolley is also pre-wired whichreduces installation time.

Right: Typical power system shipped on steel frame.

Ph: 402-339-9300/800-521-4888 www.insul-8.com

Solutions from a Single Source

CANADA175 Boulevard J.F. Kennedy

St. Jerome, Quebec J7Y 4B5

Phone: (450) 565-9900

Toll Free: (800) 667-2487

Fax: (450) 432-6985e-mail: [email protected]

USA10102 F Street

Omaha, NE 68127

Phone: (402) 339-9300

Toll Free: (800) 521-4888

Fax: (402) 339-9627e-mail: [email protected]

AUSTRALIA:14 England Street

Dandenong, Victoria 3175

Phone: (3) 9706 88 44

Fax: (3) 794 92 98e-mail: [email protected]

Distributed By:

SPRING DRIVEN

REELS

SLIP RINGS PENDANTS

CONDUCTOR BAR

CONDUCTOR BAR

DRIVES

Please visit our websites at:

www.insul-8.comwww.drivecon.com

ISO 9001 Certified

CF003 01/02

MN

catalog cable festoon

Documents

angle iron

sealed ball

5standard

0standard

spark resistant

galvanized

pole terminal

cond wire