ELECTROBAR ELITE ®

CONDUCTOR BAR SYSTEMS

C O L U M B U S M c K I N N O N C O R P O R A T I O N
 Conductor bar systems are a practical, effective, and economical way to deliver power
to overhead cranes, workstation cranes, hoists, monorails, and other types of moving
equipment. Whether you need power for a standard top-running hoist application, a
curved monorail, or a special lifting or positioning application, Columbus McKinnon’s
safe and versatile range of conductor bar systems can help.
Magnetek ELECTROBAR Elite is our most advanced conductor bar system available.
® ®

Designed for easy installation, low maintenance, and improved safety, ELECTROBAR
Elite provides a lower total system cost for your applications. The system also features a
lightweight, compact design, making it ideal for use in tight spaces where other systems
will not fit.

2
ELECTROBAR ELITE ®

CONDUCTOR BAR SYSTEMS

FEATURES & BENEFITS

LOWER TOTAL SYSTEM COST — EASY TO MAXIMUM VERSATILITY
INSTALL AND MAINTAIN
•C
 ompact design allows installation in tight
• ELECTROBAR Elite reduces installation time spaces where other systems will not fit.
when compared with traditional conductor bar
•N
 o expansion joints are required in systems
systems.
under 460 feet.
• Maintenance requirements are minimized,
•L
 ow friction collectors ease movement of
providing lower installation and lifetime
workstation bridge cranes.
maintenance costs.
• I P23 rated so it is finger safe and resistant to
•S
 ystem components are lightweight and rigid,
rain at up to a 60° angle from vertical.
allowing a single person to assemble the
system. •R
 ubber dust exclusion strips are available
to minimize contamination of conductors
•L
 ine elements are easily slipped into the snap-
through the line element trolley gap.
in hangers, which mount with one threaded rod
to the hanger bracket. •H
 igh speed collectors available for speeds
exceeding 325 fpm.
•J
 oint covers, power feeds, and end caps
simply snap together over the line elements. •S
 tandard line element operating temperature
Much of the assembly is done by hand, using a range -20°C to 55°C.
minimum number of tools. •H
 igh temperature line elements available for
•L
 ine elements are connected with torque temperatures above 55°C to 75°C.
limiting bolts whose heads twist off when •C
 urved elements available with minimum 32”
enough torque has been applied. This assures radius.
proper connection of conductors with smooth
transitions from section to section for the •V
 entilated line elements prevent condensation
collector brushes. build up.

•C
 ollector brushes are normally serviced • Trolley introduction gates ease maintenance
by removing the trolley from the end of the of collector trolleys when three or more
system. The brushes are easy to remove and bridges are used on a single crane runway.
put back into the trolley, allowing a rapid return
to service after maintenance. The collector
assembly can only be put back into the line
element in one orientation, preventing cross
connecting power and ground.

Many parts of the ELECTROBAR Elite system are made from plastic insulating materials. The insulating covers for normal temperature use are made
of PVC. The plastic hangers are made from thermoplastic materials as are the plastic parts of the collectors. If your application uses materials or
chemicals that can evaporate or get into the air and onto the conductor bar parts, please consult with our Magnetek service team about the suitability
of this product in your environment.

3
 LINE ELEMENTS

8 5
3
6 7

4
1
2

10
9

STANDARD FEATURES & BENEFITS

Item Page Number
• Operating temperature range -20°C to 55°C
• Collector trolley captured by line element and 1. Line Element 5
can’t be disengaged
• Snap together covers, power feeds, and 2. End-Line Power Feed 6
hangers
3. In-Line Power Feed 6
• Lightweight, rigid construction
• Ease of installation, lower total system cost, 4. Joint Cover 7
and low maintenance
• Improved safety (finger safe rating of IP23) 5. End Cap 7

6. Sliding Hanger 7

7. Anchor Hanger 7

8. Mounting Bracket 8

9. Collector 9

10. Tow Bracket 10

11. Dust Exclusion Seals 10

12. Transfer Funnels 11

13. Expansion Element 12

4
LINE ELEMENTS

1. 4-POLE AND 5-POLE LINE ELEMENTS

• L ine Elements are constructed of self-extinguishing PVC with copper conductors; 20 Amp Line elements use steel conductors
• Maximum rated operational voltage 600 volts, 460V for high temperature line elements

4-POLE LINE ELEMENTS 5-POLE LINE ELEMENTS

Catalog Length Weight Catalog Length Weight
Description Description
Number Ft M Lbs Kg Number Ft M Lbs Kg
FM-4204 13.123 4 15.00 6.80 FM-5204 13.123 4 15.88 7.20
FM-4203 20 Amp, 9.843 3 11.25 5.10 FM-5203 20 Amp, 9.843 3 11.91 5.40
4-Pole Line 5-Pole Line
FM-4202 Element 6.562 2 7.50 3.40 FM-5202 Element 6.562 2 7.94 3.60
FM-4201 3.281 1 3.75 1.70 FM-5201 3.281 1 3.97 1.80
FM-4604 13.123 4 15.88 7.20 FM-5604 13.123 4 16.76 7.60

FM-4603 60 Amp, 9.843 3 11.91 5.40 FM-5603 60 Amp, 9.843 3 12.57 5.70
4-Pole Line 5-Pole Line
FM-4602 Element 6.562 2 7.94 3.60 FM-5602 Element 6.562 2 8.38 3.80

FM-4601 3.281 1 3.97 1.80 FM-5601 3.281 1 4.19 1.90

FM-4104 13.123 4 17.64 8.00 FM-4104 13.123 4 18.48 8.38

FM-4103 100 Amp, 9.843 3 13.23 6.00 FM-4103 100 Amp, 9.843 3 13.86 6.29
4-Pole Line 5-Pole Line
FM-4102 Element 6.562 2 8.82 4.00 FM-4102 Element 6.562 2 9.24 4.19

FM-4101 3.281 1 4.41 2.00 FM-4101 3.281 1 4.62 2.10

FM-4134 13.123 4 21.16 9.60 FM-5134 13.123 4 23.80 10.80

FM-4133 130 Amp, 9.843 3 15.87 7.20 FM-5133 130 Amp, 9.843 3 17.85 8.10
4-Pole Line 5-Pole Line
FM-4132 Element 6.562 2 10.58 4.80 FM-5132 Element 6.562 2 11.90 5.40

FM-4131 3.281 1 5.29 2.40 FM-5131 3.281 1 5.95 2.70

FM-8284-TR 13.123 4 31.72 14.39 FM-8285-TR 13.123 4 37.04 16.80

FM-8283-TR 200 Amp, 9.843 3 23.79 10.79 FM-8289-TR 200 Amp, 9.843 3 27.78 12.60
4-Pole Line 5-Pole Line
FM-8282-TR Element 6.562 2 15.86 7.19 FM-8286-TR Element 6.562 2 18.52 8.40

FM-8281-TR 3.281 1 7.93 3.60 FM-8287-TR 3.281 1 9.26 4.20

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 SYSTEM COMPONENTS

2. & 3. POWER FEEDS

• Designed to feed power to the system either from the end or along the line element run
• Allows for quick power connection with a snap together cover
• Power feed selection based upon location and power feed cord diameter

END-LINE POWER FEED

Catalog Cable Diameter Weight

Description
Number
In Mm Lbs Kg
FM-1200 20-100 Amp, 4 & 5-Pole, M25 Cable Grip 0.51 to 0.75 13 to 19 0.9 0.41
FM-1230 20-100 Amp, 4 & 5-Pole, M32 Cable Grip 0.59 to 0.98 15 to 25 0.9 0.41

End-Line Feed Box FM-1250 20-100 Amp, 4 & 5-Pole, M40 Cable Grip 0.83 to 1.25 21 to 32 0.9 0.41

IN-LINE POWER FEED

Catalog Cable Diameter Weight

Description
Number
In Mm Lbs Kg
FM-1300 20-100 Amp, 4 & 5-Pole, M25 Cable Grip 0.51 to 0.75 13 to 19 0.66 0.30
FM-1330 20-100 Amp, 4 & 5-Pole, M32 Cable Grip 0.59 to 0.98 15 to 25 0.66 0.30
In-Line Feed Box

IN-LINE POWER FEED WITH JUNCTION BOX

Catalog Cable Diameter Weight
Description
Number
In Mm Lbs Kg
FM-1332 20-100 Amp, 4 -Pole, M40 Cable Grip 0.83 to 1.25 21 to 32 3.75 1.70
In-Line Feed Box FM-1329 20-100 Amp, 5 -Pole, M40 Cable Grip 0.83 to 1.25 21 to 32 3.75 1.70
with Junction Box

PRE-FABRICATED POWER FEED

ON 1 METER LINE ELEMENT (NOT SHOWN)

Catalog Cable Diameter Weight

Description
Number
In Mm Lbs Kg
FM-1313 130 Amp, 4-Pole with 2 Meter Connecting Cables 0.63 16 17.60 7.98

FM-8299-TR 200 Amp, 4-Pole with 2 Meter Connecting Cables 0.81 21 28.60 12.97

FM-1317 130 Amp, 5-Pole with 2 Meter Connecting Cables 0.63 16 19.80 8.98

FM-8294-TR 200 Amp, 5-Pole with 2 Meter Connecting Cables 0.81 21 34.32 15.57

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SYSTEM COMPONENTS

4. JOINT COVER 5. END CAP

• Self centering, • Snaps over the end

snap-on joint cover, of a line element and
no tools required includes end stop to
for assembly prevent over travel
of collector

JOINT COVER END CAP

Catalog Weight Catalog Weight

Description Description
Number Lbs Kg Number Lbs Kg

Joint Covering Flange for FM-2400 End Cap for All Systems 0.66 0.30
FM-2000 0.44 0.20
All Systems

6. & 7. MOUNTING HANGERS

• Galvanized steel • Anchor Hangers

construction and secure the line
premounted M8 x element to the
60 bolt structure
• Snaps onto line • Galvanized steel
element construction and
premounted M8
x 60 bolt with (2)
anchoring screws

SLIDING HANGER ANCHOR HANGER

Catalog Weight Catalog Weight

Description Description
Number Lbs Kg Number Lbs Kg

FM-1510 Snap-In Hanger, New Style 0.22 0.10 FM-1500 Anchor Hanger, New Style 0.22 0.10

Two (2) required for 20 to 130 Amp, 4 meter line elements. Two (2) required for 20 to 130 Amp, 4 meter line elements.
Three (3) required for 200 Amp, 4 meter line elements.

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 SYSTEM COMPONENTS

8. HANGER MOUNTING BRACKETS

WEB MOUNTING BRACKETS

Catalog “X” Dimension Weight

Description
Number In Mm Lbs Kg

BKS-W15-G Galvanized, Web Mounted, 15 in. 11 279 1.5 0.68

Mounting Brackets
BKS-W18-G Galvanized, Web Mounted, 18 in. 14 356 1.9 0.86

BKS-W24-G Galvanized, Web Mounted, 24 in. 20 508 2.2 1.00

FLANGE MOUNTING BRACKETS

Catalog “X” Dimension Weight

Horizontal Web Mount Description
Number In Mm Lbs Kg

BKS-F18-G Galvanized, Web Mounted, 18 in. 18 457 2.2 1.00

BKS-F24-G Galvanized, Web Mounted, 24 in. 24 610 2.7 1.22

Horizontal Flange Mount To order Flange Mount Brackets with two mounting clamps, add “A” after F18 or F24.

WORKSTATION BRIDGE CRANE

MOUNTING BRACKETS
“X”
Catalog “X” Dimension Weight
Description
Number In Mm Lbs Kg
Galvanized, for
BKS-GBL-2K 15 381 3.5 1.59
Workstation Bridge 4 in. x 4 in. tube
Crane Bracket
Galvanized, for
BKS-GBL-4K 18 457 4.5 2.04
5.5 in. x 4.5 in. tube
Galvanized, for
BKS-GBL-4K2 18 457 4.5 2.04
6 in. x 6 in. tube

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COLLECTOR ASSEMBLIES

9. STANDARD (RIGID) COLLECTOR TROLLEY

• Collector selection based on amperage requirements

• The collector assembly can be installed only in one orientation to the line element, ensuring the ground conductor and
the ground collector brush are always together
• The brushes snap into the collector assembly for quick and easy replacement
• Factory stocked collectors come standard with 1 meter of cable and are for systems without curves or dust protection

RIGID COLLECTOR TROLLEY

FOR 4-POLE SYSTEMS

Catalog Amp Weight

Description
Number Rating Lbs Kg
Single Collector Trolley with
FM-2043-1M 400 1.32 0.60
1 Meter Cable
Double Collector Trolley with
FM-4047-1M 80 2.42 1.10 Single Collector
Two 1 Meter Cables
Triple Collector Trolley with
FM-5049-1M 120 3.52 1.60
Three 1 Meter Cables
Cleaning Collector Trolley
FM-4514 N/A 0.88 0.40
(not pictured)

RIGID COLLECTOR TROLLEY

FOR 5-POLE SYSTEMS
Double Collector
Catalog Amp Weight
Description
Number Rating Lbs Kg
Single Collector Trolley with
FM-2051-1M 40 1.32 0.60
1 Meter Cable
Double Collector Trolley
FM-4051-1M 80 2.42 1.10
with Two 1 Meter Cables
Triple Collector Trolley with
FM-5059-1M 120 3.52 1.60
Three 1 Meter Cables
Cleaning Collector Trolley
FM-4525 N/A 0.88 0.40
(not pictured) Triple Collector

Collectors shown are for standard applications composed of straight line

elements. For all other applications, please consult the factory for an
application specific quotation.

REPLACEMENT PARTS
Catalog
Description
Number
FM-0022 Carbon Brush
FM-0118 Brush for Cleaning Collectors

9
7
 COLLECTOR ASSEMBLIES

10. TOW BRACKETS

• Tow Brackets (standard carriers)

provide the mechanical link between
the collector trolley and the moving
equipment.
• Galvanized steel brackets to be Single Collector
mounted onto a round tow bar 0.79’’ Tow Bracket Double Collector
(20mm) to 1.97’’ (50mm) or a square Tow Bracket
tow bar 0.19’’ (20mm) to 1.57’’ (40mm)
• Junction boxes are available for tow
brackets. Consult the factory for more
information.
TOW BRACKETS

Catalog Weight
Description
Number Lbs Kg
FM-1600 Tow Bracket for Single Trolley 1.3 0.59
Triple Collector
Tow Bracket FM-1610 Tow Bracket for Double Trolley 2.4 1.09
FM-1630 Tow Bracket for Triple Trolley 5.7 2.59

DUST EXCLUSION SEALS

11. DUST EXCLUSION SEALS

Rubber dust exclusion seals are available for line elements,

in-line power feeds, joint covers, curves, trolley inlet
gates and expansions. They are not used for end of line
components, since the trolley does not pass through them.
The catalog number is made by adding an LV to the end of
the standard catalog number.

For example, a 20 Amp line element with dust exclusion

seals is FM-4204-LV instead of the standard FM-4204. The
seals can be added to stocked line elements, which allows
good turnaround time for systems requiring dust exclusion.
Suitable for use up to 55°C.

Silicone grease is used on the inside of the rubber seals to

ease the travel of the collector trolleys.

Catalog Weight
Description
Number Lbs Kg
FM-0287 Dust Seal Grease 0.5 0.23

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TRANSFER FUNNELS

12. TRANSFER FUNNEL LINE ELEMENTS

• Transfer funnel is pre-mounted on 1 meter line

element. Special lengths available upon request
• Short funnels may be used for switch
applications from 0.375’’ to 1’’ gap
• Long funnels may be used when gap distance
exceeds 1’’
• Special collector trolleys and tow brackets are
required. Contact factory
• Funnels designed to accommodate ground to
the right or left
• IP23 finger safe rated

SHORT FUNNEL ASSEMBLIES LONG FUNNEL ASSEMBLIES

Catalog Amp Catalog Amp
Description Description
Number Rating Number Rating

FM-2501 4-Pole 1 Meter Element Ground Right 20 FM-2551 4-Pole 1 Meter Element Ground Right 20

FM-2502 4-Pole 1 Meter Element Ground Left 20 FM-2552 4-Pole 1 Meter Element Ground Left 20

FM-2517 4-Pole 1 Meter Element Ground Right 60 FM-2567 4-Pole 1 Meter Element Ground Right 60

FM-2518 4-Pole 1 Meter Element Ground Left 60 FM-2568 4-Pole 1 Meter Element Ground Left 60

FM-2525 4-Pole 1 Meter Element Ground Right 100 FM-2575 4-Pole 1 Meter Element Ground Right 100

FM-2526 4-Pole 1 Meter Element Ground Left 100 FM-2576 4-Pole 1 Meter Element Ground Left 100

FM-2533 4-Pole 1 Meter Element Ground Right 130 FM-2583 4-Pole 1 Meter Element Ground Right 130

FM-2534 4-Pole 1 Meter Element Ground Left 130 FM-2584 4-Pole 1 Meter Element Ground Left 130

FM-2541-TR 4-Pole 1 Meter Element Ground Right 200 FM-2591-TR 4-Pole 1 Meter Element Ground Right 200

FM-2542-TR 4-Pole 1 Meter Element Ground Left 200 FM-2592-TR 4-Pole 1 Meter Element Ground Left 200

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 EXPANSION ELEMENTS

13. EXPANSION ELEMENT

4-POLE EXPANSION ASSEMBLY

Catalog Length Weight
Description
Number Ft M Lbs Kg
4-Pole Expansion
FM-8020 6.56 2 14.11 6.40 • The expansion element is designed to absorb
Element 20 Amp
the difference in expansion between the support
4-Pole Expansion structure and the electrification line.
FM-8060 6.56 2 14.33 6.50
Element 60 Amp
• Expansions are needed in 20 Amp applications
4-Pole Expansion longer than 460 feet (140 meters).
FM-8100 6.56 2 16.75 7.60
Element 100 Amp
• Expansions are needed in 60 Amp and 100 Amp
4-Pole Expansion applications longer than 494 feet (150 meters).
FM-8013 6.56 2 19.18 8.70
Element 130 Amp • Expansions are needed in 130 Amp and 200
4-Pole Expansion Amp applications longer than 820 feet (250
FM-8290-TR 6.56 2 25.13 11.40 meters).
Element 200 Amp
• When expansions are used, an extra single
5-POLE EXPANSION ASSEMBLY collector trolley must be used on each bridge.

Catalog Length Weight

Description
Number Ft M Lbs Kg
5-Pole Expansion
FM-8520 6.56 2 15.00 6.80
Element 20 Amp
5-Pole Expansion
FM-8560 6.56 2 15.43 7.00
Element 60 Amp
5-Pole Expansion
FM-8510 6.56 2 18.07 8.20
Element 100 Amp
5-Pole Expansion
FM-8513 6.56 2 21.60 9.80
Element 130 Amp
5-Pole Expansion
FM-8291-TR 6.56 2 28.88 13.10
Element 200 Amp

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MH3034 ELECTROBAR Elite Brochure 4/22
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