Conductor Bar Systems

Conductix-Wampfler Conductor Bar Systems for crane electrification and other mobile equipment.

Additional information

Conductor bar is a safe and economical method to provide electric power to mobile equipment. We were the first to offer "8-bar" insulated conductor bar for crane electrification in the US back in 1952.
Now you can choose from six unique systems for virtually any need from 100 to 1500 amperes and more.  We've manufactured the brands you have trusted for the past 60 years:  Insul-8, Wampfler, and Saf-T-Bar - now part of the Conductix-Wampfler conductor bar family.

Safe-Lec 2 Conductor Bar

Additional information

SAFE-LEC 2 ®  V-Contact Conductor Bar System - the new standard in overhead crane electrification.  SL 2 is ideal for monorail and material handling system electrification as well.

Safe-Lec 2 provides these great benefits:

  • Positive Tracking - "V-contact" in the bar guides the shoe and provides continuous conductivity.  Collector arms articulate in a wide range of motion to help keep the collector shoe in contact with the rail.
  • Safe Insulation -  Conductor bar is insulated for IP2 "finger-safe" operation.
  • Bolted Splice - a postive connection that cannot pull apart over time.
  • Minimum Number of Unique Parts - same cover profile fits all bar styles!
  • Easy System Configuration - using our advanced "Quick Quote" software.

Product data

Safe-Lec 2 is easy to install

  • Multiple-Pole Hangers - holds 3 or 4 bars and install with a single bolt
  • Fewer splice joints - 14.75 foot (4.5 Meter) bar length versus the usual 10 foot.
  • Splice Joints are Pre-bolted to bar ends.
  • Fewer Expansion Joints - up to 492 foot (50 meter) runs without an expansion joint!
  • Snag-proof Collector Cables - cables are integrated within the collector arm
  • Slotted hanger supports - to acccommodate system alignment variations

Curved Systems: 

60" minimum radius; factory curved

Current Capacity Range:

100 amps, 125 amps, 200 amps, 160 amps, 250 amps, 315 amps, and 400 amps capacities (600 volts max.)
 
Maximum Speed:

1,200 feet per minute (365.8 meters/minute)

OPTIONS:

  • Heater wire systems
  • Stainless steel hardware
  • Green bonding (ground) conductor covers and black "UV resistant" outdoor covers

Downloads

Catalog - Conductor Bar, Safe-Lec2 / Hevi-Bar II

Spec Data Sheet - Conductor Bar


Manual - Conductor Bar - Safe Lec 2


Hevi-Bar II Conductor Bar

Additional information

The Conductix-Wampfler Hevi-Bar II Conductor Bar System delivers the kind of reliable, high-capacity crane rail electric service needed by factories, mills, storage yards, people movers, and other rigorous applications.

Hevi-Bar II features:

  • Effective Heat Dissipation - uses surface area rather than mass to dissipate heat generated by high current conditions
  • Mounting versatility - can be mounted with the bars next to one another (horizontal) or one above the other (vertical)
  • A choice of Insulating Covers - standard orange PVC, green PVC for the bonding (ground) conductor bar (500 amp only), black UV-resistant PVC for outdoor use, and medium or high heat versions to withstand higher ambient temperatures
  • Ease of Installation - a limited number of modular components
  • Low Maintenance and Long Life - this is truly an "install it once and forget about it" conductor bar system
  • Easy System Configuration - using our advanced "Quick Quote" software!

Product data

Current Capacity Range:

500 amps, 700 amps, 1000 amps, and 1500 amps, at 600 volts.
 
Maximum Running Speed: 

2,000 feet/minute (609.6 meters/minute)

OPTIONS:

  • Heater wire systems (500 amp only)
  • Stainless steel hardware
  • Green bonding (ground) conductor covers, black "UV resistant" outdoor covers, and high-heat covers
  • Curved systems - Contact the Factory

DURA-COAT - For Corrosive Environments

Hevi-Bar II is available with our optional DURA-COAT finish. Dura-Coat is a specially formulated coating that combines a ceramic compound with an epoxy binder to provide superior corrosion resistance and adhesion to the base materials. The entire bar is coated except in the stainless steel collector shoe running area; the insulating cover is applied over the coating.

All metal parts of the collector arm are coated. Arms are not coated as they are made from high-strength glass filled polymer.

DURA-COAT is an ideal conductor bar for galvanizing and electro-plating lines, chemical plants, smelters, foundries and cast houses, coke and ore handling cranes, and oxidizing/electro-winning facilities.

Downloads

Catalog - Conductor Bar, Safe-Lec2 / Hevi-Bar II

Spec Data Sheet - Conductor Bar


Manual - Conductor Bar, Hevi Bar II


Insul 8 8-Bar Conductor Bar

Additional information

60 years ago Conductix-Wampfler, under the name Rucker Insul 8®  Corporation, was the first to develop the original "8-Bar" electric conductor bar. This innovative design greatly improved the safety of overhead crane electrification. Since then, hundreds of miles of 8-Bar systems have been installed and are in use all over the world. It is truly the industry standard!

Conductix-Wampfler Insul 8®  8-Bar Systems are:

  • UL listed and CSA Approved
  • Fast and Easy to Install
  • Easy to Maintain
  • Complete with a Wide Selection of Special Options - curved bar, corrosion resistant systems, pick-up guides, and a wide variety of brackets.
  • Special Applications Experience - over 60 years of field use
  • Easy System Configuration - using our advanced "Quick Quote" software!

Product data

Current Capacity Range: 

40 amp, 90 amp, 110 amp, 250 amp, 350 amp, and 500 amp capacities at 600 volts max.
 
Maximum Running Speed:  

900 feet/minute (274.3 meters/minute)

Options:

  • Standard (160°F), Medium-Heat (250° F), and High-Heat (400°F) Covers
  • Stainless Steel Hardware
  • Green Ground Conductor Covers
  • Black "UV resistant" Covers; Curved Systems to 18" Radius (Standard Covers).

Downloads

Catalog - Conductor Bar, Insul-8 Bar/Saf-T-Bar

Bulletin - 8-Bar 4th Ground Bar


Spec Data Sheet - Conductor Bar


Manual - Conductor Bar, 8-Bar


Side-Contact Conductor Bar

Additional information

Conductix-Wampfler Side Contact Conductor Bar is a variation of the 8-Bar system designed for lateral (side) entry of the collector. UL / CSA listed. Side Contact is ideal when there is insufficient room for standard "bottom entry" mounting and/orconductors must be more closely spaced than standard 8-Bar allows.

Side-Contact Conductor Bars:

  • Come with cover and connector pins installed. Copper and Laminate Bars also come with Joint Keepers.
  • Have expansion sections that are required for every 350 feet (106.7m) for 40, 90, and 110 amp systems, or 250 feet (76.2m) for 250 or 350 amps to compensate for thermal expansion.
  • Are easy to configure using our advanced "Quick Quote"software!

Product data

Current Capacity Range: 

40 amps, 90 amps, 110 amps, 250 amps, and 350 amps

Maximum Running Speed: 

900 feet/minute  (274.3 meters/minute)

Factory installed covers are available in:

  • Rigid PVC: -10° F to 160° F (- 23.30° C to 71.10° C)
  • Medium Heat: - 25° F To 250° F (- 31.70° C to 121.10° C)

Downloads

Manual - Conductor Bar, Side Contact

Spec Data Sheet - Conductor Bar



Saf-T-Bar Series C Conductor Bar

Additional information

This is the original Howell Corporation Saf-T-Bar® Series C conductor bar system. Bars are roll-formed of galvanized steel or copper/steel laminate (250A) or copper (300A and 350A). The “U” shaped contact surface ensures positive tracking of the collector shoe and ensures good contact throughout the travel of the system. The standard material is supplied in 10 ft lengths with all necessary joining hardware. Installation is simple and requires only a jointing tool to connect the rails.

Product data

Current Capacity Range: 

90 amps, 110 amps, 250 amps, 300 amps, 350 amps

Maximum Running Speed: 

900 feet/minute (274.3 meters/minute)

Bar Material:

  • CA110 1010 galvanized steel
  • CA250 Steel/copper
  • CA300 Copper
  • CA350 Electrolytic copper

Bar Features:

  • Skin-tight insulation runs cooler, will not deform under clamping pressure.
  • Metal Guideways assure positive tracking of collector shoe
  • Flat contact surface for long conductor wear and
  • Greatest possible sliding contact area

Collector Features:

  • Contact shoe made with sintered copper and graphite, self-lubricating, draws current to collectors. Flat contact surface.
  • Pantograph spring suspension of collector provides even pressure to shoe throughout stroke, yielding maximum electrical and mechanical performance.

Atmospheric specifications:

In wet and icy atmospheres, the system can be shielded with a protective hood for additional protection. In dirty and dusty atmospheres, mount the conductor in down-turned position (bottom entry - i.e. collector enters up into the bottom of the rail)

Insulating cover options:

  • Standard is orange rigid PVC extrusion, 160°F (71°C). Heat distortion point at 260 psi, self-extinguishing.
  • Medium heat cover of red Lexan extrusion can be specified when necessary, 260°F (127°C). Heat distortion point at 260 psi, self extinguishing.
  • High heat fiberglass cover is available, 375°F (191°C) heat distortion.

Downloads

Catalog - Conductor Bar, Insul-8 Bar/Saf-T-Bar

Spec Data Sheet - Conductor Bar


Manual - Conductor Bar, Saf-T-Bar, Series C


Saf-T-Bar Conductor Bar, T-Series

Additional information

This is the original Howell Corporation Saf-T-Bar T Series system. This system is unique to Conductix-Wampfler and features a captive collector concept resulting in an extremely compact system. The conductor bars are supplied with pre-mounted joints. Using the jointing tool, adjoining rails can be connected quickly and easily. Special spring collectors are constructed of a chromium-copper material which ensures optimized collector wear.

Features:

  • Rapid installation. Slide-on or snap-on joint clips and multiple bar assemblies. One unit mounting for quick, easy installation
  • Skin-tight, rigid PVC insulation runs cooler, will not deform under clamp pressure
  • Twin contact conductor. Two internal contact grooves track the collector. Provides for excellent ventilation with high current capacity for its weight Hand-safe design

Product data

Current Capacity: 

65 amps

Material: 

TA65 Galvanized Steel Rail with Rigid PVC Insulation rated at 160°F

Other features:

  • Collector is "captured" within the "twin-contact" conductor profile of the bar, assuring good contact
  • Compact dimensions for efficient use of minimal space
  • One square inch per conductor
  • Modular design of this system facilitates use of multiple conductors easily mounted in various combinations with
  • Multiple collector assemblies are possible

Atmospheric Specifications:

Series T Saf-T-Bar is not recommended for dirty applications.

Insulating Hanger Option:

A spool mount insulator hanger option is available as an alternative.

Insulating Cover Options:

Insulating covers are rigid PVC extrusions rated at 160°F operating temperature and Lexan extrusions rated at 260°F. Both materials are self-extinguishing.

Downloads

Catalog - Conductor Bar, Insul-8 Bar/Saf-T-Bar

Spec Data Sheet - Conductor Bar


Manual - Conductor Bar, Saf-T-Bar, Series T


Conductix-Wampfler Tower Buss system for down-tower power transmission

Tower Buss Conductor Bar - for Wind Turbines

Additional information

Handling and installing power cables in wind turbine towers is difficult and costly. The solution is Tower BussTM by Conductix-Wampfler.

Conductix-Wampfler has applied its extensive knowledge and experience in rigid conductor design to develop the Tower Buss modular conductor bar system. It can be pre-assembled into the tower before it is erected - completely eliminates the hassle of installing main cables after erection.

Product data

Tower Buss has these great features:

High-strength, conductor-grade aluminum:

  • Wide range of ampacities
  • More cost effective than copper cable
  • Requires few supports
  • Flexes with tower deflection

CPVC or polycarbonate insulating jacket:

  • Tough and durable
  • UL recognized materials

Polycarbonate snap-in supports:

  • High mechanical and dielectric strength
  • Provides quick installation of buss bars

Modular sections:

  • Can be pre-installed into tower sections while they are still on the ground
  • Can be installed in controlled factory conditions versus in the field
  • Lower installation costs versus cable
  • Eliminates the hazard of accidentally dropping cables during installation

Tower Buss has been successfully installed and tested in numerous wind tower systems!

Contact Conductix-Wampfler for more information about our innovative Tower Buss solution!