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ERAIL ELECTRIFIED RAIL SYSTEMS
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ERAIL ELECTRIFIED RAIL SYSTEMS

Knight ERAIL enclosed conductor rail: 60 A four-pole power in the rail, up to 1,360 kg and 9.1 m unspliced. Capacity charts and accessories from FULLSHARP.

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Description

ERAIL Electrified Rail Systems

ERAIL Electrified Rail Systems

Series: ERAD4000 / ERAD6000 / ERAD7000

The Electrified Rail System is a complete overhead power supply solution that can be combined with Knight Servo Systems, VFD trolleys, power tools and other electrical equipment.

The ERAD series is a fully enclosed electrical system that eliminates the build-up of festooned power cable. Power runs through the conductor bar (ERail), mounted on top of the ERAD4000, ERAD6000 or ERAD7000 aluminium rail. ERail comes standard with 4 poles rated at 60 Amp, 240/480V – enough to run several systems on a single rail assembly.

ERail can also be fitted to the side of the aluminium rail, reducing overall height and allowing standard Knight rail to be used instead of a custom top-mounted profile. It can also be retrofitted to an existing Knight system to eliminate electrical festooning without replacing the rail.

ERAD aluminium rail is supplied in lengths of up to 25 ft [9.1 m] with no splice required. Maximum system capacity is up to 3,000 lbs [1,360 kg].

*Note: The top-mounted style is patent pending. ERail comes standard with 4 poles rated at 60 A, 240/480V. Accessories can be positioned anywhere along the rail.

Features & Benefits

Features

  • Patent pending (top-mounted style).
  • Fully enclosed electrical system.
  • ERail electrical capacity: up to 60 Amp / 690 Volt.
  • Horizontal curved sections available.
  • Maximum capacity: up to 3,000 lbs [1,360 kg].
  • Meets international standards.
  • Enhanced protection against electric shock.
  • Knight proprietary adjustable hangers – flexible levelling during installation.

Benefits

  • Side-mounted rail option.
  • Eliminates trolley festooning and hanging power cable.
  • Simplifies installation – the power rail is built into the suspension.
  • No tow bar required.
  • Compact stacked design – no separate load rail and power rail to install.
  • Twice the capacity of competing systems.
  • Retrofits to existing Knight Global systems.
  • Saves installation time and cost.

System Components

What Makes Up an ERAIL System

  1. ERail – conductor bar: four poles rated at 60 A, carrying power along the full length of the system.
  2. ERail conductor trolley: travels inside the ERail alongside the Knight load trolley, using copper graphite shoes for power and for control voltage above 35 V.
  3. ERAD4000 / ERAD6000 / ERAD7000 rail: ergonomic aluminium rail paired with Knight load trolleys. Lengths up to 25 ft [9.1 m] with no splice, capacity up to 3,000 lbs [1,360 kg].
  4. Suspension points: adjustable hangers and end trucks support both the load rail and the ERail. Mount to I-beam, C-channel, angle iron and other structures.
  5. ERail end caps & stops: fit to the ends of the ERail. The redundant end cap prevents the load trolley and the ERail trolley from running off the rail.
  6. Power supply end feed: the incoming power connection for the ERail, supplied standard with four poles.

Capacity by Model
*Deflection criteria: Each hanger span is tested for the maximum single-point load that meets a deflection ratio of 1:350 (1″ of deflection over 350″ of length), 1:450 (1″ over 450″), 1:550 (1″ over 550″).

ERAD4000 Capacity – by Hanger Span

Hanger Span (ft / m) 1:350 Ratio 1:450 Ratio 1:550 Ratio
lbs kg lbs kg lbs kg
5 / 1.52 1,140 517 1,140 517 1,140 517
6 / 1.83 945 429 945 429 945 429
7 / 2.13 810 367 810 367 790 358
8 / 2.45 705 320 705 320 600 272
9 / 2.74 625 283 575 261 470 213
10 / 3.05 560 254 460 209 375 170
11 / 3.35 490 222 375 170 300 136
12 / 3.66 405 184 310 141 245 111
13 / 3.96 340 154 255 116 205 93
14 / 4.27 285 129 215 98 170 77
15 / 4.57 240 109 180 82 140 64
16 / 4.88 205 93 150 68 120 54
17 / 5.18 175 79 130 59 100 45
18 / 5.49 150 68 110 50 80 36
19 / 5.79 130 59 90 41 65 29
20 / 6.10 110 50 75 34 55 25
21 / 6.40 90 41 60 27 40 18
22 / 6.71 80 36 50 23 30 14
23 / 7.01 65 29 40 18 20 9
24 / 7.32 50 23 30 14 15 7

ERAD6000 Capacity – by Hanger Span

Hanger Span (ft / m) 1:350 Ratio 1:450 Ratio 1:550 Ratio
lbs kg lbs kg lbs kg
5 / 1.52 2,030 921 2,030 921 2,030 921
6 / 1.83 1,690 767 1,690 767 1,690 767
7 / 2.13 1,445 655 1,445 655 1,445 655
8 / 2.45 1,260 572 1,260 572 1,260 572
9 / 2.74 1,115 506 1,115 506 1,115 506
10 / 3.05 1,000 454 1,000 454 895 406
11 / 3.35 905 411 900 408 730 331
12 / 3.66 825 374 750 340 605 274
13 / 3.96 760 345 630 286 510 231
14 / 4.27 700 318 535 243 430 195
15 / 4.57 600 272 455 206 365 166
16 / 4.88 520 236 395 179 310 141
17 / 5.18 450 204 340 154 270 122
18 / 5.49 395 179 295 134 230 104
19 / 5.79 345 156 255 116 195 88
20 / 6.10 300 136 220 100 170 77
21 / 6.40 265 120 190 86 145 66
22 / 6.71 230 104 165 75 125 57
23 / 7.01 205 93 140 64 105 48
24 / 7.32 180 82 120 54 85 39

ERAD7000 Capacity – by Hanger Span

Hanger Span (ft / m) 1:350 Ratio 1:450 Ratio 1:550 Ratio
lbs kg lbs kg lbs kg
5 / 1.52 3,000 1,360 3,000 1,360 3,000 1,360
6 / 1.83 3,000 1,360 3,000 1,360 3,000 1,360
7 / 2.13 3,000 1,360 3,000 1,360 3,000 1,360
8 / 2.45 2,940 1,334 2,940 1,334 2,940 1,334
9 / 2.74 2,610 1,184 2,610 1,184 2,610 1,184
10 / 3.05 2,345 1,064 2,345 1,064 2,345 1,064
11 / 3.35 2,130 966 2,130 966 2,130 966
12 / 3.66 1,945 882 1,945 882 1,945 882
13 / 3.96 1,795 814 1,795 814 1,720 780
14 / 4.27 1,660 753 1,660 753 1,475 669
15 / 4.57 1,545 701 1,545 701 1,275 578
16 / 4.88 1,445 655 1,370 621 1,110 503
17 / 5.18 1,355 615 1,205 547 975 442
18 / 5.49 1,280 581 1,065 483 860 390
19 / 5.79 1,205 547 950 431 765 347
20 / 6.10 1,105 501 845 383 680 308
21 / 6.40 995 451 760 345 610 277
22 / 6.71 895 406 685 311 545 247
23 / 7.01 810 367 615 279 490 222
24 / 7.32 735 333 555 252 440 200

Deflection Standards & Ergonomic Force Explained

What 1:350, 1:450 and 1:550 Mean

Each rail span is tested to determine the maximum single-point load allowed to reach a given deflection:

  1. 1:350 – 1 inch of deflection per 350 inches of rail length (more flexible, heavier loads).
  2. 1:450 – 1 inch of deflection per 450 inches of rail length (stiffer, better ergonomics).
  3. 1:550 – 1 inch of deflection per 550 inches of rail length (stiffest, for the most demanding requirements).

Operating Force Estimation Formula

  • For a quick estimate of the ergonomic operating force required, use: Fs = 0.009 × Total Mass = maximum force (lbf) to overcome inertia.
  • The force required to keep the load moving is 0.35 × the breakaway force (Fs).
  • Example – a mass of 250 lbs (113.4 kg):
    • Fs = 0.009 × 250 = 2.25 lbf (1.02 kg) to overcome inertia.
    • Fk = 2.25 × 0.35 = 0.79 lbf (0.36 kg) to keep it moving.

Product Videos

* ERAIL Electrified Rail Systems – operating demo

Knight Global application overview

Accessories
General Accessories
EMRMA6172 cord clamp

EMRMA6172

Cord Clamp
  • Protects the power cable as the trolley travels.
  • Fits ERAD4000 / 6000 / 7000.

Weight: 0.14 lbs [0.06 kg]

EMRTA6196 conductor trolley

EMRTA6196-XXX-X-X

ERail Conductor Trolley
  • 240VAC 1P / 480VAC 3P.
  • 15 / 20 / 30 A ratings.
  • 1 m or 3 m cable.
  • Supplied with an EMRMA6172 cord clamp.
  • Fits ERAD4000 / 6000 / 7000.

Weight: 1.5 lbs [0.68 kg]

KSAA1080 ERail cleaning trolley

KSAA1080

ERail Cleaning Trolley
  • Nylon brushes – will not damage the rail.

Weight: 20 lbs [9 kg]

Load Trolleys
EMRTA4176 servo trolley

EMRTA4176

Servo Trolley – ERAD4000
  • Max capacity 1,140 lbs [517 kg].
  • Fits ERAD4000.

Weight: 5.7 lbs [2.56 kg]

EMRTA4190 load trolley

EMRTA4190

Load Trolley – ERAD4000
  • Max capacity 1,140 lbs [517 kg].
  • Fits ERAD4000.

Weight: 5.5 lbs [2.48 kg]

EMRTA4194 low-headroom load trolley

EMRTA4194

Low-Headroom Load Trolley – ERAD4000
  • Max capacity 1,140 lbs [517 kg].
  • Fits ERAD4000.

Weight: 4.9 lbs [2.22 kg]

EMRTA6176 servo trolley

EMRTA6176

Servo Trolley – ERAD6000
  • Max capacity 2,030 lbs [920 kg].
  • Fits ERAD6000.

Weight: 11.2 lbs [5.06 kg]

EMRTA6190 load trolley

EMRTA6190

Load Trolley – ERAD6000
  • Max capacity 2,030 lbs [920 kg].
  • Fits ERAD6000.

Weight: 6.1 lbs [2.77 kg]

EMRTA6192 load trolley with yoke

EMRTA6192

Load Trolley + Yoke – ERAD6000
  • Rotates on the X and Y axes.
  • Fits ERAD6000.

Weight: 6.1 lbs [2.77 kg]

EMRTA7176 servo trolley

EMRTA7176

Servo Trolley – ERAD7000
  • Max capacity 3,000 lbs [1,360 kg].
  • Fits ERAD7000.

Weight: 16.8 lbs [7.62 kg]

EMRTA7190 load trolley

EMRTA7190

Load Trolley – ERAD7000
  • Max capacity 3,000 lbs [1,360 kg].
  • Fits ERAD7000.

Weight: 11.9 lbs [5.38 kg]

EMRTA7194 low-headroom load trolley

EMRTA7194

Low-Headroom Load Trolley – ERAD7000
  • Max capacity 3,000 lbs [1,360 kg].
  • Fibreglass-filled nylon wheels, sealed bearings.
  • Fits ERAD7000.

Weight: 11.5 lbs [5.22 kg]

End Trucks

Rotating end trucks suspend both the load rail and the ERail. The yoke design pivots on the X and Y axes, so the bridge cannot bind against the runway. Each part number is supplied in a -4000 / -6000 / -7000 variant according to the runway rail it travels inside (RAD4110 / RAD6110 / RAD7510). Low-profile versions reduce the stack-up height under the runway.

EMRES4181 rotating end truck

EMRES4181

Rotating End Truck – ERAD4000
  • Suspends the ERAD4000 rail and the ERail.
  • Yoke pivots on the X and Y axes.
  • EMRES4181-4000 runs inside RAD4110 rail.
  • Max capacity 1,140 lbs [517 kg].

Weight: 37.7 lbs [17.11 kg]

EMRES4185 low profile rotating end truck

EMRES4185

Low Profile Rotating End Truck – ERAD4000
  • Suspends the ERAD4000 rail and the ERail.
  • Reduced stack-up height.
  • EMRES4185-4000 runs inside RAD4110 rail.
  • Max capacity 1,140 lbs [517 kg].

Weight: 37.7 lbs [17.11 kg]

EMRES6181 rotating end truck

EMRES6181

Rotating End Truck – ERAD6000
  • Suspends the ERAD6000 rail and the ERail.
  • Yoke pivots on the X and Y axes.
  • -4000 / -6000 / -7000 for RAD4110 / RAD6110 / RAD7510.
  • Max capacity 2,030 lbs [920 kg].

Weight: 37.7 lbs [17.11 kg]

EMRES6185 low profile rotating end truck

EMRES6185

Low Profile Rotating End Truck – ERAD6000
  • Suspends the ERAD6000 rail and the ERail.
  • Reduced stack-up height.
  • -4000 / -6000 / -7000 for RAD4110 / RAD6110 / RAD7510.
  • Max capacity 2,030 lbs [920 kg].

Weight: 37.7 lbs [17.11 kg]

EMRES7181 rotating end truck

EMRES7181

Rotating End Truck – ERAD7000
  • Suspends the ERAD7000 rail and the ERail.
  • Yoke pivots on the X and Y axes.
  • -4000 / -6000 / -7000 for RAD4110 / RAD6110 / RAD7510.
  • Max capacity 3,000 lbs [1,360 kg].

Weight: 38.7 lbs [17.56 kg]

EMRES7185 low profile rotating end truck

EMRES7185

Low Profile Rotating End Truck – ERAD7000
  • Suspends the ERAD7000 rail and the ERail.
  • Reduced stack-up height.
  • -4000 / -6000 / -7000 for RAD4110 / RAD6110 / RAD7510.
  • Max capacity 3,000 lbs [1,360 kg].

Weight: 38.4 lbs [17.42 kg]

Hangers
EMRHA4161 C-channel hanger

EMRHA4161

C-Channel Hanger – ERAD4000
  • Concentric / eccentric load.
  • Adjustable height.
  • Fits ERAD4000.

Weight: 8.7 lbs [3.9 kg]

EMRHA6160 C-channel tube hanger

EMRHA6160

ERail Tube Style C-Channel Hanger
  • Autophoretic ACC 900® corrosion protection.
  • Steel parallel or perpendicular to the rail.
  • Fits ERAD4000 / 6000 / 7000.

Weight: 5.2 lbs [2.36 kg]

EMRHS6162 I-beam hanger

EMRHS6162

I-Beam Hanger 2–7 in – ERAD6000
  • Flange 51–178 mm.
  • Adjustable height.
  • Fits ERAD6000.

Weight: 18.3 lbs [8.29 kg]

EMRHS7162 I-beam hanger

EMRHS7162

I-Beam Hanger 2–7 in – ERAD7000
  • Flange 51–178 mm.
  • Adjustable height.
  • Fits ERAD7000.

Weight: 24.7 lbs [11.2 kg]

EMRHS6163 I-beam hanger non-ERail side

EMRHS6163

I-Beam Hanger 2–7 in – Non-ERail Side
  • For the non-electrified side of an ERail system.
  • Flange 51–178 mm, max flange thickness 7/16 in.
  • Autophoretic ACC 900® corrosion protection.
  • Fits ERAD4000 / 6000 / 7000.

Weight: 13.8 lbs [6.26 kg]

EMRHA4165 C-channel hanger sub-assembly

EMRHA4165

C-Channel Hanger Sub-Assembly – ERAD4000
  • Cross steel parallel or perpendicular to the rail.
  • Fits ERAD4000.

Weight: 6.6 lbs [3 kg]

End Caps & Stops

Every rail run is closed with an end cap. The standard end cap assembly stops the load trolley leaving the rail; the redundant end cap adds a second barrier that also stops an end truck and keeps dust out of the ERail; the power feed versions do the same job and carry the incoming supply into the ERail. Choose the part number that matches the rail series.

EMRAA6170 ERail end cap

EMRAA6170

ERail End Cap
  • Closes the end of the ERail conductor bar.
  • Keeps dust out of the ERail.
  • Fits ERAD4000 / 6000 / 7000.

Weight: 0.07 lbs [0.03 kg]

EMRAA4182 end cap assembly

EMRAA4182

End Cap Assembly – ERAD4000
  • Attaches to the end of the ERAD4000 rail and ERail.
  • Stops the load trolley running off the rail.

Weight: 0.9 lbs [0.42 kg]

EMRAA4183 power feed end cap assembly

EMRAA4183

Power Feed End Cap Assembly – ERAD4000
  • Incoming power connection for the ERail.
  • Stops the load trolley running off the rail.

Weight: 5.4 lbs [2.46 kg]

EMRAS4171 redundant end cap assembly

EMRAS4171

Redundant End Cap Assembly – ERAD4000
  • Stops a load trolley or end truck exiting the rail.
  • Also keeps dust out of the ERail.

Weight: 3.1 lbs [1.39 kg]

EMRAS4179 power feed redundant end cap assembly

EMRAS4179

Power Feed Redundant End Cap – ERAD4000
  • Power feed plus redundant stop in one assembly.
  • Stops the load trolley running off the rail.

Weight: 5.4 lbs [2.46 kg]

EMRAA6182 end cap assembly

EMRAA6182

End Cap Assembly – ERAD6000
  • Attaches to the end of the ERAD6000 rail and ERail.
  • Stops the load trolley running off the rail.

Weight: 4.5 lbs [2.06 kg]

EMRAA6183 power feed end cap assembly

EMRAA6183

Power Feed End Cap Assembly – ERAD6000
  • Incoming power connection for the ERail.
  • Stops the load trolley running off the rail.

Weight: 4.6 lbs [2.10 kg]

EMRAS6171 redundant end cap assembly

EMRAS6171

Redundant End Cap Assembly – ERAD6000
  • Stops a load trolley or end truck exiting the rail.
  • Also keeps dust out of the ERail.

Weight: 4.5 lbs [2.06 kg]

EMRAS6179 power feed redundant end cap assembly

EMRAS6179

Power Feed Redundant End Cap – ERAD6000
  • Power feed plus redundant stop in one assembly.
  • Stops the load trolley running off the rail.

Weight: 4.6 lbs [2.10 kg]

EMRAA7182 end cap assembly

EMRAA7182

End Cap Assembly – ERAD7000
  • Attaches to the end of the ERAD7000 rail and ERail.
  • Stops the load trolley running off the rail.

Weight: 2.4 lbs [1.08 kg]

EMRAA7183 power feed end cap assembly

EMRAA7183

Power Feed End Cap Assembly – ERAD7000
  • Incoming power connection for the ERail.
  • Stops the load trolley running off the rail.

Weight: 2.4 lbs [1.08 kg]

EMRAS7171 redundant end cap

EMRAS7171

Redundant End Cap Assembly – ERAD7000
  • Stops end trucks and trolleys running off the rail.
  • Also keeps dust out of the ERail.

Weight: 13.8 lbs [6.2 kg]

EMRAS7179 power feed redundant end cap assembly

EMRAS7179

Power Feed Redundant End Cap – ERAD7000
  • Power feed plus redundant stop in one assembly.
  • Stops a load trolley or end truck exiting the rail.

Weight: 5.4 lbs [2.46 kg]

Rail Splices
EMRHA4178 rail splice

EMRHA4178

ERail Splice Kit – ERAD4000 / 6000
  • Splices two sections of ERail and of ERAD rail.
  • Bolted, no welded bosses required.
  • Easy access to the bolt heads.

Weight: 5.8 lbs [2.64 kg]

EMRHA7178 rail splice

EMRHA7178

ERail Splice Kit – ERAD7000
  • Splices two sections of ERail and of ERAD7000 rail.
  • Bolted, no welded bosses required.
  • Fits ERAD7000.

Weight: 11.4 lbs [5.17 kg]

*Note: All accessories listed are compatible with the ERAIL electrified rail range. Contact FULLSHARP for help selecting the right accessories for your application.


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