Catalog Cable Festoon

Insul-8 Mobile Electrification
Cable Reels Conductor Bar Festoon Pendants Drives Slip Rings
Solutions From A Single Source
Cable Festoon
Systems for Power and Control
For the Electrification of:

Overhead Cranes Monorails Transfer Cars Trippers Stacker / Reclaimers
This catalog showcases a sampling of the most commonly used festoon systems. If you dont see what youre looking for, please ask us.
INSUL-8 CRANE ELECTRIFICATION

Typical C-Track Festoon Systems (Power & Control) For Overhead Crane Installation
3 4 5 1 2 6 7 8 9 10
Insul-8 also
offers a Quick Disconnect Control Box Trolley
11
17
16 15
14 12
13
1 2 3 4 5 6 7 8
Fixed End Junction Box Terminal Strips End Clamp Track Hanger Clamp Intermediate Trolley Cross Arm Support Beam Clamp
(inside junction box)
9 10 11 12 13 14 15 16 17
Track Control Box Trolley Track Joint Pendant Cable Pendant Push-Button Station Tow Arm Tow Trolley Flat PVC Cable End Stop MOTIV-8TM
Cable Connectors
FESTOONING SYSTEMS FROM INSUL-8 1

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TABLE OF CONTENTS
THIS CABLE
CATALOG PROVIDES A WIDE VARIETY OF FESTOONING SOLUTIONS FOR ELECTRIFYING OVERHEAD CRANES. AND CONNECTORS Flat Cable and Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Insul-8 also offers a full range of round cable and hose to meet your requirements STRETCHED WIRE ROPE SYSTEMS LOAD 40 LBS SPEED: 200 FPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
C-TRACK SYSTEMS Standard Duty LOAD: 40 LBS SPEED: 250 FPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Standard Duty Pre-assembled Festoon Kits LOAD: 40 LBS SPEED: 250 FPM . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21 Heavy Duty LOAD LOAD: 80 LBS SPEED: 500 FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 SQUARE BAR SYSTEMS Standard Duty LOAD: 45 LBS SPEED: 250 FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Heavy Duty LOAD: 175 LBS SPEED: 250 FPM
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Flat Cable Trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Round Cable Trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
I-BEAM SYSTEMS Series 200
LOAD: 55LBS SPEED: 200 FPM Flat Cable Trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Series 250 LOAD: 95 LBS SPEED: 250 FPM Flat Cable Trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Round Cable Trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Series 300 LOAD: 150 LBS SPEED: 300 FPM Flat Cable Trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Series 350 LOAD: 175 LBS SPEED: 350 FPM Flat Cable Trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Round Cable Trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 18
FESTOON ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUSH BUTTON PENDANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FESTOON KITS LOAD: 40 LBS SPEED: 250 FPM . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 PRE-ASSEMBLY (LEARN MORE ABOUT IT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IF YOU DONT SEE WHAT YOURE LOOKING FOR, PLEASE ASK US. Insul-8 also provides customized systems for unique applications including Heavy Duty Festoon systems.
19 19 21 22
ABOUT OUR SYSTEMS

FESTOON SYSTEMS are a clean, economical and efficient method of managing power and
control cables for mobile equipment.
FESTOON SYSTEMS are generally used on overhead cranes for the transmission of power and
control 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 portal and container cranes. Insul-8s festoon systems run on wire rope, c-track, square bar and I-Beams, with trolleys able to support static loads up to 175 pounds and up to 1,100 pounds with Heavy-Duty festoon systems. Insul-8 festoon systems are designed to support and protect flat 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 for harsh, aggressive environments.
MOTIV-8TM
FESTOONING SYSTEMS FROM INSUL-8

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FLAT CABLE AND CONNECTORS

Flat Cable
Required cable length equals track plus 10% plus length required for end connections Cable Part Number Yellow PVC Jacket 23958Y 26550Y 21814Y 26698Y 22542Y 22994Y 21815Y 26005Y 26110Y 22607Y 21813Y 23324Y 31580 31734 31772 Shielded Flat Cable Cable Size Number of Conductors 4 4 4 4 4 4 4 8 8 8 12 12 4 AWG Wire Size #2 #4 #6 #8 #10 #12 #14 #12 #14 #16 #14 #16 #16 Continuous Duty Rating 0 0 at 30 C (86 F) Ambient Amps* 120 90 70 50 40 30 25 21 17 15 17 15 Control Cables No Short Time Rating Short Time Rating Amps** 60 Min. 148 111 83 63 49 36 31 30 Min. 173 130 94 69 52 40 32 No. of Strands per Conductor 665 420 266 168 105 65 41 65 41 65 41 65 65 Weight per Foot (lbs) Nominal Dimensions Unshielded 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
1.27 .75 .60 .42 .24 .16 .12 .32 .22 .18 .34 .27 .16
* 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 Cable Connectors

For Termination of Cable at Power Source or Junction Box. Construction: Aluminum Body / Rubber Bushing
Catalog
Number 35838 35838B 35837 35835C 35835B 35835 35837B 35837C 35837D 35838C 35838D 35838G 35837E 35837F
No. of Cables 1 1 1 1 1 1 1 1 1 1 1 2 2 2
Cable Size
No. of Cond Wire Size
(AWG)
NPT 2 2 1.5 1 1 1 1.5 1.5 1.5 2 2 2 1.5 1.5
Ref Cable # 26550Y 21814Y 26698Y 22542Y 22994Y 21815Y 26005Y 26110Y 22607Y 21813Y 23324Y 26005Y 26110Y 22607Y
Catalog
Number 35838E 35838F 35837G 35837K 35837J 35837H 35837L 35837M
4 4 4 4 4 4 8 8 8 12 12 8 8 8
#4 #6 #8 #10 #12 #14 #12 #14 #16 #14 #16 #12 #14 #16
No. of Cables 2 2 1 1 1 1 1 1 1 1 2 2
Cable Size
No. of Cond Wire Size
(AWG)
NPT 2 2 1.5 1.5 1.5 1.5 1.5 1.5
Ref Cable # 21813Y 23324Y 22607Y 21815Y 26110Y 21815Y 22607Y 22542Y 26110Y 22542Y 22607Y 22994Y 26110Y 22994Y
12 12 8 4 8 4 8 4 8 4 8 4 8 4
#14 #16 #16 #14 #14 #14 #16 #10 #14 #10 #16 #12 #14 #12
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
Catalog Number 03147 03146 03145
Cable Opening 1.60 1.10 .75
Knockout Diameter 2.00 1.37 1.00
Dimension A 6.17 4.5 4.09
Weight lbs. .40 .10 .06

Dim A

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MOTIV-8TM
STRETCHED WIRE FESTOON KITS

Stretched Wire Rope Festoon Systems are well suited for light duty applications where an intermediate support structure is not available. Economical and dependable, stretched wire rope systems provide electrification to small cranes, moving hoists and jib cranes. LOAD: 10 LOAD: 20
LBS LBS
(1 (2
WHEEL) MAX. WHEEL) MAX.
SPEED: 200 SPEED: 200
FPM MAX. FPM MAX.

SW 2 SW 6 SW 5 SW 4
FOR FLAT CABLE:

Kit Part Number Max. Cable Width
Single Wheel Double Wheel
Max. Span (In Feet) 20 40 60 80 100
3/4 Max.
1-3/4 Max.
No. of Trolleys in Kit

3 6 9 13 17
SW 1 SW 3
24862 24863 24864 24865 24866
24867 24868 24869 24870 24871
SW 15
SW 14
Kits include all components listed below:

Catalog # SW 1 SW 2 SW 3 SW 4 SW 5 22950 23288 22830 22828 22825 22826 Component
Nylon Coated Wire Rope, 1/4 dia.
Catalog # SW 6 SW 14 SW 15 22836 22834 22835
Component Anchor Bracket Flat Cable Saddle < 3/4 (20mm) wide Flat Cable Clip
Hardware Kit Tow Bar Tow Trolley (2 wheel) Trolley (1 wheel) Trolley (2 wheel)
LOAD: 10 20
LBS LBS
(1 (2
WHEEL) MAX. WHEEL) MAX.
SPEED: 200 SPEED: 200
FPM MAX. FPM MAX.

SW 2 SW 6 SW 10 SW 8 SW 9 SW 7
FOR HOSE & ROUND CABLE:

Kit Part Number
Cable / Hose O.D. 3/16 - 3/8 Max. 3/8 - 9/16 Max. 9/16 - 3/4 Max.
SW 1 SW 3
Max Span (In Feet) 20 40 60 80 100
*1 wheel
2 wheel
*1 wheel
2 wheel
*1 wheel
2 wheel
No. of Trolleys in Kit 3 6 9 13 17
SW 11
24872 24873 24874 24875 24876
24887 24888 24889 24890 24891
24877 24878 24879 24880 24881
SW 12
SW 13
24892 24893 24894 24895 24896
24882 24883 24884 24885 24886
24897 24898 24899 24900 24901
Catalog # SW 1 SW 2 SW 3 SW 6 SW 7 22950 23288 22830 22836 22829
Component
Nylon Coated Wire Rope 1/4 Dia.
Catalog # SW 8 SW 9 SW 10 SW 11 SW 12 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 ) SW 13
Catalog # 22833
Component Cable Clip (9/16 to 3/4)
Hardware Kit Tow Bar Anchor Bracket Tow Trolley (2 wheel)
MOTIV-8TM

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STANDARD DUTY C-TRACK SYSTEM COMPONENTS

14 Gauge Galvanized Steel Stainless Steel
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 polypropylene galvanized steel and aluminum.
Load: 40 lbs max. Speed: 250 fpm max.
Catalog Number Galvanized Steel 22209 21909 36678 36679 Stainless Steel 27725 27724 Weight Pounds 10 20 2lbs/ft 1lb/ft Description
14 Gauge C-Track
10 ft. Section 20 ft. Section Cross Arm Support Bracket: 36678 = 12 Gauge from 12 to 48 in 6 36679 = 14 Gauge increments (please specify)
Track Joint Assembly

One required for each track section per run less one.
21954 31856
27726 32059
.75 .75
Joint clamp for secure attachment and proper alignment of track sections. Includes four bolts, lock washers and nuts. Welded Joint Assembly for joining track section.
Track Hanger Clamp Assembly

One required for each cross arm support bracket for each track run. 5 spacing.
28510 35707 22005
28741
.40 .51 .81
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 track to cross arm support. (Not Shown)
Anchor Clamp
28511 35706 23381
28742
.40 .40 .20
One required per track run Designed to hold track in place. For use with Cross Arm Support Bracket. Includes all required hardware. (Not Shown)
End Stop
27727
One required for power system, two required for control systems with control trolley.
22264
.38
Beam Clamp for Cross Arm Support

Two required for each cross arm support bracket.
End Clamp
One required for each track run at storage end of track.
21957 28616 27728
.56 .42 .56
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.
Plastic trolleys, tow trolleys and end clamp suitable for use on galvanized steel systems are noted with

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MOTIV-8TM
STANDARD DUTY C-TRACK SYSTEM COMPONENTS

14 Gauge Galvanized Steel Stainless Steel (Continued)
Catalog Number Galvanized Steel Stainless Steel Weight Pounds

Tow Trolley
Load rating: 40 lb max. One required for each piece of moving equipment to be electrified.
Description
22168 28614 32060
1.12 .70 1.12
Plated steel trolley with 2.75 Dia. saddle with cut out for tow bar. Plastic trolley with 2 Dia. plastic saddle with cut out for tow bar. Black anodized aluminum tow trolley with 4 stainless steel wheels and hardware.
Tow Bar
22830
1.2
One required for each tow trolley. For mounting on moving equipment 16 long.
Control Box Trolley
22203B 32166 28315 28314 34876 28314K
2.75 3.0 9.0 9.0 .20
Two trolleys and one steel saddle mounted on bracket plus fittings to attach control box. (Control box not included.) Same as 22203 except with stainless steel trolleys and stainless steel wheels and hardware.
Junction Boxes and Terminal Strips

8 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 13 Stainless Steel Rated at: NEMA 4X 12-pole terminal strip.
Control Unit Trolley with Quick Disconnect
2366 (16 Pin) 2367 (24 Pin)
5.28 5.59
Lead 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
Cable Trolley - 5
Load rating 40 lbs max.
21941 32062
1.0 .89
5-inch trolley with 4 steel shielded ball bearing wheels, 2.75 Dia. steel saddle and hardware. Black anodized aluminum body and trolley with stainless steel wheels and hardware.
Cable Trolley - 3
21991 28615 32061
.70 .40 .70
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 bearing wheels, 2 Dia plastic saddle. (not shown) Black anodized aluminum body and saddle with stainless steel wheels and hardware.
MOTIV-8TM

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HEAVY DUTY C-TRACK SYSTEM COMPONENTS

12 Gauge Galvanized Steel Flat Cable Components
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 with aluminum saddle only. Load: 80 lbs max. Speed: 500 fpm max.
Catalog Number
Weight Pounds 20.0 40.0

10 ft. Section 20 ft. Section
Description
12 Gauge C-Track
22210 21805
Track Joint Assembly
21806
1.08
One 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.
Track Hanger Clamp Assembly
28512
.45
One required for each angle iron bracket for each track run. 10 spacing. Designed to be mounted on angle iron brackets with one mounting hole.
Anchor Clamp
28513
.45
One required per track run. Designed to hold track in place.
End Stop
28508
.20
One required for Power System, two required for Systems with Control Trolley.
End Clamp
One required for each track run at storage end of track. Aluminum saddle 4 dia. with clamp and hardware to secure cable 5 1/4 wide.
21932
1.63
Cable Trolley
21802
3.0
Trolley load rating 80 lbs max. 8 high strength aluminum body with 4 dia aluminum saddle. Trolley bumpers.

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MOTIV-8TM
HEAVY DUTY C-TRACK SYSTEM COMPONENTS

12 Gauge Galvanized Steel Flat Cable Components
Continued
Catalog Number
Weight Pounds
Tow Trolley
Description
Load rating: 80 lb max. One required for each piece of moving equipment to be electrified.
22169
4.75
8 trolley and aluminum saddle 4 dia. with cut out for tow bar.
22008
2.63
Tow Bar
One required for each tow trolley. For mounting on moving equipment 24 long.
Control Box Trolley
22350
12.5
Two trolleys and one aluminum saddle 4 dia. mounted on bracket plus fittings to attach control box. (Junction Box sold separately below.)
28315 28314 34876
9.0 9.0 .20
8 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.
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.
MOTIV-8TM

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STANDARD DUTY SQUARE BAR COMPONENTS

Catalog Number
Standard 24525
Stainless Steel
Weight Pounds 28.0 28.0 28.0
Description
Track (Square Bar)
20 ft. Section, H.R. Steel Track 20 ft. Section, Stainless Steel Track 20 ft. Section, Galvanized Steel Track
27843 34601
Track Joint
25681
27845
.25
Track joint for secure attachment and proper alignment of track sections.
Track Hanger
25598
27846
.50
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
End Stop
25596
27847
.75
Designed to be located between end clamp and intermediate trolley.
Tow Trolley
25594
28621
3.0
Load rating 45 lbs max. One required per system. 4 long body with cut out for Tow Bar.
28315 28314 34876 28314K
9.0 9.0 .20
8 x 10 x 4 steel junction box NEMA 13. (Terminial Strip not included) 8 x 10 x 4 steel junction box for control box trolley. (Includes 12 pole terminal strip.)
Galvanized Steel Rated at: NEMA 13 Stainless Steel Rated at: NEMA 4X
12-pole terminal strip.
Cable Trolley
25593
28622
2.5
Trolley load rating 45 lbs max. 4 long body with 2.75 dia. aluminum saddle
End Clamp
25595
28548
1.50
One required per system at storage end of track.
Curved Systems and Control Trolleys also available.

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MOTIV-8TM
HEAVY DUTY SQUARE BAR COMPONENTS

Catalog Number Standard 24526 27663 34603 Stainless Steel Weight Pounds 46.0 46.0 46.0 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
25683
27664
.50
Track joint for secure attachment and proper alignment of track sections.
Track Hanger
25667
27671
1.50
Designed to be mounted on angle iron bracket. 10 spacing. Typical 5 spacing in storage area.
Drill Fixture
25726
25726
2.0
Used for drilling holes at proper position for attachment of hangers, end clamps and end stops.
Control Box Trolley
25670
Special Unit. Available upon request.
26.0
Two trolleys and one aluminum saddle 4 dia. mounted on bracket plus fittings to attach control box. (Control box not included.)
28315 28314 34876 28314K
9.0 9.0 .20

Curved Systems also available.
8 x 10 x 4 steel junction box NEMA 13. (Terminial Strip not included) 8 x 10 x 4 steel junction box for control box trolley. (Includes 12 pole terminal strip.)
Galvanized Steel Rated at: NEMA 13 Stainless Steel Rated at: NEMA 4X
12-pole terminal strip.
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.
MOTIV-8TM

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10
HEAVY DUTY SQUARE BAR TROLLEYS FOR FLAT CABLE

Heavy Duty Square Bar Trolleys feature all-steel body construction with aluminum cable saddle. The trolleys are suitable for indoor and outdoor applications for flat cable. Standard wheels are steel with sealed ball bearings.
Tow Trolley
Cable Trolley
End Clamp
*S1
*S1
*S1
Catalog Number Weight in Pounds Description
See Chart Below 13.5

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

Standard construction consists of steel body, aluminum saddle. Maximum load per trolley is 95 lbs.
See Chart Below 8.5

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

Body: Steel-Zinc Plated Saddle: Aluminum Wheels: 1.77 O.D. Hardware: Zinc Plated Cable Pad: Neoprene Rubber Load: 175 lbs W2= Max Cable Window Width S1= Max Cable Window Height
Tow Trolley
Catalog # 45400 45400B 45401 45401B 45402 45402B 45406 45406B 45407 45407B 45410 45410B Length 11.125 11.125 12.625 12.625 15.125 15.125 12.625 12.625 15.125 15.125 15.125 15.125
Cable Trolley
End Clamp
Catalog # 45453 45453B 45454 45454B 45455 45455B 45459 45459B 45460 45460B 45463 45463B Length 7.375 7.375 8.875 8.875 11.375 11.375 8.875 8.875 11.375 11.375 11.375 11.375 4 4 4 4 4 4 6 6 6 6 8 8
Dimensions (Inches)
Saddle Dia. Width 5.25 8 5.25 8 5.25 8 5.25 8 5.25 8 5.25 8 W2 3.9 6.7 3.9 6.7 3.9 6.7 3.9 6.7 3.9 6.7 3.9 6.7 *S1 2 2 3.5 3.5 6 6 2 2 4.5 4.5 2 2
Insul-8 also offers Stainless Steel Trolleys. Please contact the factory if you are interested in these units.

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MOTIV-8TM
HEAVY DUTY SQUARE BAR TROLLEYS FOR ROUND CABLE

Heavy Duty Square Bar Trolleys feature all-steel body construction with aluminum cable saddle. The trolleys are suitable for indoor and outdoor applications for round cable. Standard wheels are steel, with sealed ball bearings.
Tow Trolley
Trolley
End Clamp
*S1
*S1
*S1
Catalog Number Weight in Pounds


Standard construction consists of steel body, aluminum saddle. Maximum load per trolley is 95 lbs.
See Chart Below 9.0

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

Body: Steel-Zinc Plated Saddle: Aluminum Wheels: 1.77 O.D. Hardware: Zinc Plated Cable Pad: Neoprene Rubber Load: 175 lbs W2= Max Cable Window Width S1= Max Cable Window Height
Tow Trolley
Catalog # 45403 45403B 45408 45408B 45411 45411B Length 11.125 11.125 12.625 12.625 15.125 15.125
Cable Trolley
End Clamp
Catalog # 45456 45456B 45461 45461B 45464 45464B Length 7.375 7.375 8.875 8.875 11.375 11.375 4 4 6 6 8 8
Dimensions (Inches)
Saddle Dia. Width 5.25 8 5.25 8 5.25 8 W2 3.9 6.7 3.9 6.7 3.9 6.7 *S1 .4 .4 .6 .6 .8 .8
Insul-8 also offers Stainless Steel Trolleys. Please contact the factory if you are interested in these units.
MOTIV-8TM

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12
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 200 fpm with loads of up to 55lbs. The Series 200 I Beam System can be strategically used indoors where festoon cable systems are required to operate on an I Beam. These I Beam trolleys are sand cast aluminum with nylon wheels.
Tow Trolley
Cable Trolley
End Clamp
24829 2.75
24830 2.0
Standard construction consists of 5 long body, 2.75Dia. x 4 wide saddle. Maximum load per trolley is 55 lbs.
24828 .75
One End Clamp required per system. Bolted to I Beam with (2) 1/4-20 x .25 mounting bolts.

Body: Sand cast Aluminum Saddle: 2.75 Dia. Aluminum Wheels: Nylon Cable Pad: Neoprene Rubber Load: 55 lbs. max Speed: 200 fpm. max Maximum I Beam Flange Width: 4.50
NOTE:

Trolleys available for I Beam flange width up to 6.25 Trolleys with steel wheels available, simply order: 28904 / 2.0 lbs Tow Trolley 33530 / 2.75 lbs Cable Trolley 24828 / .75 lbs End Clamp
For trolleys without anti-kick rollers simply add B to the end of the part numer.
I Beam (customer provided)
Cable Trolley End Clamp (Fixed) Cable Pigtail for Hookup
Tow Webbing
Tow Trolley
Festoon Cable

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

Series 250 I Beam Trolleys feature all-steel body construction with aluminum cable saddles. These trolleys are suitable for indoor and outdoor applications for flat cable. Wheels are available in steel for standard applications and bronze for spark resistant environments.
Tow Trolley
Cable Trolley
End Clamp
*S1
*S1
*S1

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

Standard construction consists of steel body, aluminum saddle. Maximum load per trolley is 95 lbs. Running gear with or without Anti-Lift rollers available.
See Chart Below 8.0

One End Clamp required per system. Bolted to I Beam.
Running Gear: W-Beams

Without Anti-Lift Rollers: 45197 With Anti-Lift Rollers: 45198
Beam W4 x 13 W5 x 16 W5 x 19 Code A B C Beam W6 x 9 W6 x 12 W8 x 10 Code D E K
Running Gear: S-Beams

Beam S4 x 7.7 S4 x 9.5 S5 x 10.0 Code C D E Beam S6 x 12.5 S6 x 17.25 S7 x 15.3 Code G H J
(Consult factory for bronze rollers and other beam sizes!) Specifications & Dimensions
Body: Steel-Zinc Plated Saddle: Aluminum Wheels: 40mm Steel Flanged Anti-Lift Bearing: 1.38 Dia. SteelHardware: Zinc Plated Cable Pad: Neoprene Rubber Load: 95 lbs W2= Max Cable Window Width S1= Max Cable Window Height
Tow Trolley
Trolley
End Clamp
Dimensions (Inches)
MOTIV-8TM

Ph: 402-339-9300/800-521-4888 www.insul-8.com
14
SERIES 250 I BEAM FOR ROUND CABLE

Series 250 I Beam Trolleys feature all-steel body construction with aluminum cable saddles. These trolleys are suitable for indoor and outdoor applications for round cable. Wheels are available in steel for standard applications and bronze for spark resistant environments.
Tow Trolley
Cable Trolley
End Clamp
S1
S1
S1


See Chart Below 8.5



(Consult factory for bronze rollers and other beam sizes!) Specifications & Dimensions
Body: Steel-Zinc Plated Saddle: Aluminum Wheels: 40mm Steel Flanged Anti-Lift Bearing: 1.38 Dia. SteelHardware: Zinc Plated Cable Pad: Neoprene Rubber Load: 95 lbs W2= Max Cable Window Width S1= Max Cable Window Height
Tow Trolley
Cable Trolley
End Clamp
Catalog # 45156 45156B 45161 45161B 45164 45164B Length 7.375 7.375 8.875 8.875 11.375 11.375 4 4 6 6 8 8
Dimensions (Inches)
Saddle Dia. Width 5.25 8 5.25 8 5.25 8 W2 3.9 6.7 3.9 6.7 3.9 6.7 S1 .4 .4 .6 .6 .8 .8

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

The economical Series 300 I Beam Trolleys for flat cable are designed to run on S3 x 5.7#, S3 x 7.5# or S4 x 7.7# I beams only. The saddle is suspended from the trolley by a pivot mechanism which allows the cable package to sway during crane operation providing smoother operation. Lead trolleys are supplied with anti-lift rollers as standard.
Catalog Number
Weight Pounds
Description Tow Trolley
34366
9.0
One required per system. Complete with Anti-Lift Rollers positioned as Lead Trolley in system is equipped with cut out box for engagement of tow bar from mobile consumer. Length= 8.00
Cable Trolley 34364 5.0

Standard construction consists of steel body, steel saddle. Maximum load per trolley is 150 lbs. Length= 5.50
End Clamp 34365 5.0

One End Clamp required per system. Positioned at end of system and clamped to I Beam. Length= 7.77
Single Control Trolley 34407 5.0

Single trolley suitable for mounting junction box. Length = 5.5
Control Box Trolley 34925 13.0

Two trolleys and one steel saddle mounted on bracket plus fittings to attach control box Junction Box sold separately (See Page 10.)
Length = 26.25
Specifications
Body: Low Carbon Steel Saddle: Low Carbon Steel Finish: Zinc Plated w/yellow Dichromate Seal Hardware: 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
MOTIV-8TM

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

Series 350 I Beam Systems are designed for flat 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. The trolleys are provided with side guide and anti-lift rollers to withstand the most demanding applications. The trolleys are suitable for indoor and outdoor applications for flat cable. Wheels are available in steel for standard applications.
Tow Trolley
Cable Trolley
End Clamp
*S1
*S1
*S1





Need another beam size? Call us.

Body: Steel-Zinc Plated Saddle: Aluminum Wheels: 2 Dia. Crowned Steel Anti-Lift Bearing: 1.38 Dia. SteelHardware: Zinc Plated Cable Pad: Neoprene Rubber Load: 175 lbs Max. W2= Max Cable Window Width S1= Max Cable Window Height
Tow Trolley
Trolley
End Clamp
Dimensions (Inches)

Ph: 402-339-9300/800-521-4888 www.insul-8.com
MOTIV-8TM
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 are suitable for indoor and outdoor applications for round cable. Wheels are available in steel for standard applications.
Tow Trolley
Cable Trolley
End Clamp
*S1
*S1
*S1





(Consult factory for other beam sizes!)

SteelHardware: Zinc Plated Body: Steel-Zinc Plated Saddle: Aluminum Cable Pad: Neoprene Rubber Wheels: 2 Dia. (40mm) Steel Flanged Load: 175 lbs W2= Max Cable Window Width Anti-Lift Bearing: 1.38 Dia. S1= Max Cable Window Height
Tow Trolley
Cable Trolley
End Clamp
Catalog # 45156 45156B 45161 45161B 45164 45164B Length 7.375 7.375 8.875 8.875 11.375 .11.375 4 4 6 6 8 8
Dimensions (Inches)
Saddle Dia. Width 5.25 8 5.25 8 5.25 8 W2 3.9 6.7 3.9 6.7 3.9 6.7 *S1 .4 .4 .6 .6 .8 .8
MOTIV-8
TM

Ph: 402-339-9300/800-521-4888 www.insul-8.com
18
FESTOON ACCESSORIES
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.
Catalog Number 24690 24690B 24690C 24690D 24690E 24690F Nominal Weight (lbs) .28 .40 .51 .63 .74 .85
Tow Cable
Optional item used in both High Speed and Outdoor applications. Designed for use on: Heavy Duty C-Track Heavy Duty Square Bar 250 Series I Beam 350 Series I Beam
Length 4-6 6-8 8-10 10-12 12-14 14-16
Description
Tow Webbing
03159
As Required
Optional item used in both High Speed and Outdoor applications ideal for systems in spark resistant environments. Ordered by the foot.
.18 lbs/ft
Designed for use on: Standard Duty C-Track Standard Duty Square Bar 200 Series I Beam 300 Series I Beam
TW H1 W
Catalog Number 40619J 40619K H1&H2 4.5 4.5 Dimensions: Inches W TW 7.8 5.1 6.7 10.6
Flat Cable Organizer

Optional item for systems in order to prevent flat cables within the loops from becoming tangled or caught 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.
H2
Round Cable Organizer

L1 L2 W D
D Cable Dia. Range 40600P Up to .80 40600Q Up to .80
Catalog Number
L1 6.0 8.8
L2 3.9 6.7
Wt (lbs.) .75 1.1
Optional item for systems in order to prevent round cables within loops from becoming tangled or caught during operation. Either one or two per loop may be required. 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.
Push button pendants are used in conjunction with conductor bar, festoon systems or reels 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.

Ph: 402-339-9300/800-521-4888 www.insul-8.com
MOTIV-8TM
C-TRACK FESTOON KITS

Pre-configured, standard duty C-Track festoon system kits provide a simple method for ordering complete crossbridge power systems for crane applications. If you need a kit with other cable combinations and trolley styles, just ask us. Kits can also be ordered pre-assembled by simply adding the letter P to the end of the system part number. See page 22. Example: 36670E = 60 power system 36670EP = 60 pre-assembled power system
FOR POWER SYSTEMS

Hanger Clamp Track
Trolley Fixed End Pigtail End Stop
End Clamp FIXED END PIGTAIL
Loop Depth
Flat Cable
C-Track festoon kit using plastic trolley #28615 14 & 16 AWG - 12 Conductor Systems (#14-4C, #16-8C) Crane Span System Part Number Active Travel (feet) Storage Distance (feet) Weight (lbs) 20 36670 18.38 1.35 38 30 36670B 27.84 1.89 45 40 36670C 37.31 2.43 70 50 36670D 46.77 2.97 77 60 36670E 56.5 3.24 102
C-Track festoon kit using steel trolley #21991 14 & 16 AWG - 12 Conductor Systems (#14-4C, #16-8C) Crane Span System Part Number Active Travel (feet) Storage Distance (feet) Weight (lbs) 20 36671 18.38 1.35 38 30 36671B 27.84 1.89 45 40 36671C 37.31 2.43 70 50 36671D 46.77 2.97 77 60 36671E 56.5 3.24 102
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 length supplied includes 10 additional feet of termination purposes. Hanger supports are based on five foot centers.
MOTIV-8TM

Ph: 402-339-9300/800-521-4888 www.insul-8.com
20
C-TRACK FESTOON KITS

Pre-configured standard duty C-Track festoon system kits provide a simple method for ordering complete crossbridge control systems for crane applications. If you need a kitwith other cable combinations and trolley styles, just ask us. Push-button pendant and drop cable are to be ordered separately. Kits can also be ordered pre-assembled, by simply adding the letter P to the end of the system part number. See page 22. Example: 36672 = 20 control system 36672P = 20 preassembled control system
FOR CONTROL SYSTEMS

Track
12.01 Pendant Trolley
Trolley
End Stop
End Clamp Fixed End Pigtail
Drip Loop
Loop Depth
Flat Cable
C-track festoon kit using plastic trolley #28615 16 AWG - 16 Conductor Systems (2x#16-8C) Crane Span System Part Number Active Travel (feet) Storage Distance (feet) Weight (lbs) 20 36672 17.08 2.79 43 30 36672B 26.81 3.06 60 40 36672C 36.27 3.60 76 50 36672D 45.73 4.14 93 60 36672E 55.19 4.68 109
C-track festoon kit using steel trolley #21991 16 AWG - 16 Conductor Systems (2x#16-8C) Crane Span System Part Number Active Travel (feet) Storage Distance (feet) Weight (lbs) 20 36673 17.08 2.79 43 30 36673B 26.81 3.06 60 40 36673C 36.27 3.60 76 50 36673D 45.73 4.14 93 60 36673E 55.19 4.68 109
KITS INCLUDE THE FOLLOWING: c-track, splices, hangers, anchor hangers, trolleys, 16 pin control trolley with quick disconnect, end clamp, end stops, flat cable and connectors. Systems are calculated based on a 3 ft loop depth. Cable length supplied includes 5 additional feet of termination purposes. Hanger supports are based on five foot centers.

Ph: 402-339-9300/800-521-4888 www.insul-8.com
MOTIV-8TM
FESTOON PRE-ASSEMBLY
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 which reduces installation time.
Right: Typical power system shipped on steel frame.
MOTIV-8TM

Ph: 402-339-9300/800-521-4888 www.insul-8.com
22
Solutions from a Single Source

ISO 9001 Certified
SPRING DRIVEN REELS
SLIP RINGS
PENDANTS
CONDUCTOR BAR
Distributed By:
DRIVES Please visit our websites at:
CONDUCTOR BAR
www.insul-8.com www.drivecon.com CANADA

175 Boulevard J.F. Kennedy St. Jerome, Quebec J7Y 4B5 Phone: (450) 565-9900 Toll Free: (800) 667-2487 Fax: (450) 432-6985
e-mail: contact@insul-8.com
USA
10102 F Street Omaha, NE 68127 Phone: (402) 339-9300 Toll Free: (800) 521-4888 Fax: (402) 339-9627
e-mail: i8-info@insul-8.com
AUSTRALIA:
14 England Street Dandenong, Victoria 3175 Phone: (3) 9706 88 44 Fax: (3) 794 92 98
e-mail: insul8@peninsula.starway.net.au
CF003 01/02 MN

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What are festoon systems used for?

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Insul-8 Mobile Electrification

Cable Reels Conductor Bar Festoon Pendants Drives Slip Rings

Solutions From A Single Source

For the Electrification of:

INSUL-8 CRANE ELECTRIFICATION

FESTOONING SYSTEMS FROM INSUL-8 1

I-BEAM SYSTEMS Series 200

ABOUT OUR SYSTEMS

INSUL-8 CORPORATION offers a comprehensive line of festoon products, ranging from

FESTOONING SYSTEMS FROM INSUL-8

FLAT CABLE AND CONNECTORS

Flat Cable Connectors

NPT 2 2 1.5 1 1 1 1.5 1.5 1.5 2 2 2 1.5 1.5

NPT 2 2 1.5 1.5 1.5 1.5 1.5 1.5

Catalog Number 03147 03146 03145

Cable Opening 1.60 1.10 .75

Knockout Diameter 2.00 1.37 1.00

Dimension A 6.17 4.5 4.09

Weight lbs. .40 .10 .06

FESTOONING SYSTEMS FROM INSUL-8 3

STRETCHED WIRE FESTOON KITS

WHEEL) MAX. WHEEL) MAX.

SPEED: 200 SPEED: 200

FPM MAX. FPM MAX.

FOR FLAT CABLE:

Max. Span (In Feet) 20 40 60 80 100

No. of Trolleys in Kit

24862 24863 24864 24865 24866

24867 24868 24869 24870 24871

Kits include all components listed below:

Catalog # SW 6 SW 14 SW 15 22836 22834 22835

WHEEL) MAX. WHEEL) MAX.

SPEED: 200 SPEED: 200

FPM MAX. FPM MAX.

FOR HOSE & ROUND CABLE:

Max Span (In Feet) 20 40 60 80 100

No. of Trolleys in Kit 3 6 9 13 17

24872 24873 24874 24875 24876

24887 24888 24889 24890 24891

24877 24878 24879 24880 24881

24892 24893 24894 24895 24896

24882 24883 24884 24885 24886

24897 24898 24899 24900 24901

Catalog # SW 1 SW 2 SW 3 SW 6 SW 7 22950 23288 22830 22836 22829

Catalog # SW 8 SW 9 SW 10 SW 11 SW 12 22825 22827 25689 22831 22832

Component Cable Clip (9/16 to 3/4)

Hardware Kit Tow Bar Anchor Bracket Tow Trolley (2 wheel)

FESTOONING SYSTEMS FROM INSUL-8

STANDARD DUTY C-TRACK SYSTEM COMPONENTS

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

Track Joint Assembly

Track Hanger Clamp Assembly

28510 35707 22005

.40 .51 .81

28511 35706 23381

.40 .40 .20