PR4 4-pole conductor bar system

The Pro-Ductor PR4 is an open conductor bar system for the power supply of moving equipment. It provides reliable power transmission in demanding intralogistics applications, including high-speed warehouse automation systems with rapid acceleration and deceleration.

4-pole open conductor bar system

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Up to 4-pole configurations

Current capacity up to 200 A

No mechanical joints

Touch-safe design

PR4 conductor bar with current collector

PR4 cross section of conductor bar — Cross-section conductor bar, showing 4-poles

Copper cassette for continuous copper conductors

PCT4-4-125-BI current collector — Current collector, up to 125A

PCT4-4-70 BI + MB current collector — Current collector, up to 70A. With mounting bracket

PCT4-4-70 current collector — Current collector with overhead connection box

Connecting housing with connecting set

PR4 for warehouse automation

Modern, high‑speed cranes and machines used in warehouse automation are in general powered by a 4-pole conductor bar system (three phases + ground). The Pro‑Ductor PR4 system is one of AKAPP’s core solutions, developed for modern storage and intralogistics installations where reliability and long service life are essential.

The distinctive ‘AKAPP LongLife’ technology used in these systems is based on a wheel‑guided, spring‑supported current collectors that runs on highly stable plastic conductor rail profiles equipped with continuous copper conductors without joints. The unique interaction between the current collector and the precise rail alignment ensures minimal friction and wear, and optimal contact pressure of the carbon brushes.

Key Features

4‑pole system, up to 200A
Travel speed up to 500m/min
Continuous copper conductors for minimal wear
Wheel guided /spring support current collector
Suitable for horizontal and vertical operation
Typical applications: miniload (AKL) cranes, transfer cars

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LEARN ABOUT

Continuous Copper Technology with Akapp LongLife

AKAPP LongLife conductor bar systems use continuous copper conductors to eliminate mechanical joints and minimise transition resistance. The smooth, uninterrupted contact surface reduces heat build-up and wear on collector trolleys, ensuring reliable power transmission, longer carbon brush life and lower maintenance requirements.

Learn more about the LongLife advantages

KEY PRODUCT INFORMATION

Product details

Electrical specifications

Rated current, copper conductor models, at 80% duty cycle:

CU50 (8,82 mm2

50A

CU80 (13,75 mm2)

80A

CU125 (25 mm2)

125A

CU160 (32,50 mm2)

160A

CU200 (50 mm2)

200A

CU50/AG silver plated (8,82 mm2)

50A

Rated voltage with protective/earth conductor

690V (CE), 600V (UL)

Minimum operating parameters

Umin. 24V, Imin. 1A (manufacturer recommendation)

Number of poles

Max. 4

Conductor material

Copper

Conductor type

Flat type, continuous

Protection class

IP2X

Current collectors

All models, wheel guided:

Model: PCT4-4-70/BI

‘Side’ connection box, cable gland M40

Current capacity max. 70A (at 80% duty cycle)

Double carbon brushes per channel, individual spring supported

Model: PCT4-4-70

‘Top’ connection box, cable gland M40

Current capacity max. 70A (at 80% duty cycle)

Double carbon brushes per channel, individual spring supported

Model: PCT4-4-125/BI-40/W48

‘Side’ connection box, cable gland M40

Current capacity max. 125A (at 80% duty cycle)

Double carbon brushes per channel, individual spring supported

Model: PCT4-4-125

‘Top’ connection box, cable gland M40

Current capacity max. 125A (at 80% duty cycle)

Double carbon brushes per channel, individual spring supported

Other models, on request

Mechanical specifications

Max travel speed

500m/min, 30km/h

Phase distance

Between channel 2 and 3: 18,5mm

Between channel earth and 1, 3 and 4: 21,1mm

PR4 rail insulation material

PVC

Flammability of PR4 rail housing

flame retardant, self-extinguishing, UL 94 V0

Suspention distance (between mounting brackets)

800mm

Max. suspension distance (without SP4 support profile)

3300mm

Mounting bracket types:

With bolds/nuts, on upright/support post

SP4-MB model (see brochure)

With self-drilling screws, on upright/support post

SP4-MB/SDS model (see brochure)

Clamping on closed uprights

SP4-MBC.. models (see brochure)

Clamping on HEA-260 profiles

SP4-MBC-HEA260 model (see brochure)

System dimensions & approvals

Standard length PR4 rail, and SP4 support profile

4m.

Connection joint, PR4-J

5mm (between two PR4 rail sections)

Customized, smaller lengths (Filler pieces)

On request

System dimensions, including SP4 support profile

46x128mm

Local approvals

CE approved, UL certified

Operating conditions

Operating temperature range

-30⁰C to +60⁰C

Application

Indoor systems

AS/RS warehouse shuttle system with Akapp Pro-Ductor conductor bar

Storage and Retrieval Cranes (AS/RS)

Storage and retrieval cranes are used in automated warehouses for the handling of palletized or box size loads. As these automated storage systems depend on 24h operation power demand requires stable and 24h availability at the lowest total cost of ownership. Three-phase power is typically used to support drive and lifting systems.

The Akapp 4-pole conductor bar system PR4 provides reliable power supply for these applications, enabling stable energy transmission over long travel distances. And minimizing wear/maintenance.

Automated Stacker Cranes

Automated stacker cranes are designed for high-throughput handling of palletized goods in warehouse environments. They combine lifting, horizontal travel, and positioning functions within a single system.

These machines operate with significant power demand, particularly during acceleration and lifting movements. A three-phase power supply, such as the Akapp PR4 system, is required to support these functions under dynamic load conditions.

Automated storage and retrieval system (AS/RS) with shuttle systems using conductor bar

Miniload (AKL) cranes

Miniload cranes are widely used in automated warehouses for the handling of totes, trays, and small-load carriers. Operating at high speeds with frequent acceleration and deceleration, they maximize storage density and throughput while ensuring continuous material flow.

The Akapp PR4 conductor bar system is developed for these demanding conditions. Its 4-pole configuration supports the three-phase power requirements of modern miniload cranes, providing reliable power transmission in high-speed intralogistics environments.

Automated transfer car powered by conductor rail in a warehouse transport

Transfer cars

Transfer cars are used in industrial and intralogistics environments to transport materials and products between production lines, storage areas, or workstations. Operating on fixed tracks, they require a reliable power supply to ensure smooth movement and efficient material flow.

The Akapp PR4 conductor bar system is well suited for these applications. It provides stable power transmission during continuous travel, supporting reliable operation and efficient material handling throughout the facility.