Short answer
Note the type number from the side plate and measure the inner height, inner width, bending radius, pitch and outer dimensions of the old energy chain. Choose a replacement with at least the same inner dimensions, a radius that is not tighter and outer dimensions that are not larger, so it fits in the same place.
You replace a worn energy chain with a type that has at least the same inner dimensions, a bend that is not tighter and outer dimensions that are not larger. Then the cable package still fits, the cables are not bent more sharply and the new carrier fits in the same space. This also works if the old carrier is from another brand, because you compare dimensions, not type numbers.
This article is about finding the replacement. Whether replacing is necessary at all, or whether a few new links will do, is covered in repair or replace a cable carrier.
Why did the old energy chain fail?
Replacing it with the same type only solves the problem if the carrier was simply worn out. If it broke or wore earlier than expected, there is a cause behind it: too much weight, too long a self-supporting length, a misaligned driver, contact or an environment the material cannot withstand. That cause moves along to the new carrier.
So look at the old carrier first before you throw it away. Where is the break or wear, and is it local or along the entire length? The troubleshooting guide helps per symptom. If the material was brittle or discoloured, consider a different version, for example plastic or steel or an enclosed instead of an open carrier.
Which dimensions do you need to replace a cable carrier?
Measure on a link in the straight section and use a caliper for the inner dimensions. The more dimensions you have, the more precise the replacement.
| Size | How to measure |
|---|---|
| Inner height | Inside of the link, from the bottom to the cross connection |
| Inner width | Inside of the link, between the side walls |
| Bending radius | Height of the bend minus the outer height, divided by two |
| Pitch | Centre to centre of two hinge pins; measure ten links and divide by ten |
| Outer height | Across the outside of the link, from bottom to top |
| Outer width | Across the outside of the side walls |
| Travel length | The stroke the machine makes |
Also note how the carrier is installed: horizontal, hanging or standing. Not every type may be installed vertically. Also write down whether it is plastic or steel, open or enclosed, and how many links it has. The type number is usually on the side plate. More about the dimensions themselves in cable carrier dimensions explained.
Which rules must a replacement energy chain meet?
We use four rules. The same rules are built into the Replacement guide:
| Size | Rule | Why |
|---|---|---|
| Inner height and inner width | At least equal to now, at most 50% larger (minimum 10 mm margin) | The cable package must fit, and the carrier must still fit in the same place |
| Bending radius | Not tighter than now, at most 15% wider (minimum 10 mm margin) | The cables were chosen for that bend; a wider bend makes the carrier taller |
| Travel length | Within what the type can handle self-supporting or gliding | Otherwise the carrier sags or the guidance does not fit |
| Outer height and outer width | Not larger than now | The replacement must fit in the same space |
A worked example. Your old carrier has an inner height of 40 mm and a radius of 150 mm. A replacement may then have an inner height of 40 to 60 mm (40 plus half) and a radius of 150 to about 172 mm (150 plus 15%). A type with an inner height of 38 mm is ruled out, even if the rest fits: your cable package would then get less space than now.
Calculate it yourselfReplacement guideThe replacement for your worn or broken cable carrierOpen the replacement finderWhat if the pitch or the fixing is different?
A different pitch does not rule out a type, but it has consequences. The length is built up in different whole links, and with a different pitch or another brand the end fixing often differs.
That can usually be solved well, but you want to know before you order. With a request, a specialist checks whether the end fixing fits your machine, and we tell you in advance what needs to change on the machine. That way you are not surprised during mounting.
Many types have fixed inner widths and fixed radii. If your current dimension falls in between, choose the next size that is not tighter. Types without fixed widths are supplied to size within their range, such as the types of the M series. The UNIFLEX Advanced has a range of fixed widths per type.
What if there is no suitable type?
Sometimes every type fails on one point: the inner height is just too small, or the outer width just too large. The Replacement guide then shows the types that fail on exactly one point, so you can see where it pinches.
If the space in the machine is really too tight, or the cable package changes, choosing again is better than searching for a one-to-one replacement. In the Cable carrier configurator you start from your cables and travel, and the tool recalculates the inner dimensions, radius and length. Wisman checks that calculation free of charge.
Calculate it yourselfCable carrier configuratorCalculate, select and assemble a cable carrierOpen the cable carrier configuratorHow do you order and mount the replacement?
With your request, send the type number, the dimensions, a photo of the whole carrier in the machine and of both ends, and the number of links or the total length. If cables are added or change, include them too. Then we can assemble the carrier to size in Ruurlo, if desired complete with cables in the right layout.
Replacing several machines of the same type? Record the replacement once. Next time nothing needs to be worked out again. Rather not do the mounting yourself? We schedule assembly and installation preferably during a planned stop. Doing it yourself? Follow the steps in mounting a cable carrier.
Already have all the details? Request a quote for the replacement energy chain straight away.
Frequently asked questions
Can I replace an energy chain from another brand?
Yes. You compare dimensions, not brands or type numbers. With the inner dimensions, bending radius, pitch and outer dimensions of your current carrier, you look for a type that fits in the same place.
How do I measure the bending radius of a cable carrier?
Measure the height of the bend, from the outside at the top to the outside at the bottom, and subtract the outer height of a link. Divide the result by two.
May the replacement cable carrier have a larger radius?
A slightly wider radius is good for the cables, but makes the bend taller. That is why we allow at most 15% wider, with a margin of at least 10 mm. Tighter than now is not allowed.
Will the end fixing of the new energy chain fit my machine?
With the same type, usually yes. With a different pitch or another brand, the fixing often differs. A specialist checks this with your request and tells you in advance what needs to change.
Should I choose the same type again if the old carrier failed quickly?
No, find the cause first. If it broke or wore earlier than expected, the same will happen with the same type. The troubleshooting guide and the Carrier check help you find the cause.
Next step
Calculate it yourself or browse the range. We check your result free of charge.
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Question about this topic?
Ask Joep directly
RMO Specialist at Wisman Techniek
