PRODUCT GUIDE
TABLE OF CONTENTS BRAKES 200S General Purpose Industrial Brakes 300M AIST Mill Duty Brakes 400D Heavy−Duty Disc Brakes Motor Mounted Brakes Vertical Brakes Drop-in Brakes Custom Engineered Brakes Electro−Hydraulic Thrusters Brake Accessories Braketronic® Controller 4 4 5 5 5 6 6 6 7 7 COLLISION AVOIDANCE SYSTEMS ReFlx® Distance Detection and Collision Avoidance Systems LaserGuard™ Collision Avoidance Systems 8 8 TABLE OF CONTENTS CONTROL PRODUCTS IMPULSE®•G+ Series 4 Adjustable Frequency Crane Controls
TABLE OF CONTENTS C-Track Festoon Systems Plug & Play Festoon Hardware Heavy-Duty Aluminum Festoon Systems Heavy-Duty I-Beam Festoon Systems Mill Duty & Marine Terminal I-Beam Festoon Trolleys 27 27 28 28 29 RADIOS – CRANE AND HOIST Telemotive telePendant™ Transmitter Telemotive telePilot™ Transmitter Enrange Flex VUE® Transmitter Enrange™ Flex EX Transmitter Enrange Flex Pro™ Transmitter Enrange™ 300T Transmitter Telemotive XLTX Transmitter Telemotive MLTX2™ Transmitter Telemotive MBT Transmitter Telemot
BRAKES 200S GENERAL PURPOSE INDUSTRIAL SHOE BRAKES Features and Benefits AC, DC, HYDRAULIC, PNEUMATIC ACTUATORS • Compact size/low shaft height 4" – 19" WHEEL DIAMETERS • Designed for industrial duty applications requiring minimal maintenance 6 – 2,650 LB. FT.
BRAKES 400D HEAVY DUTY BRAKES AC, DC, HYDRAULIC ACTUATORS 8" – 50" DIAMETER DISC RANGE 50 - 30,000 LB. FT.
BRAKES DROP-IN BRAKES Replacements for a variety of manufacturer’s brakes, including GE, EC&M, Wagner, Bubenzer, Gemco, Johnson, Whiting/Sesa, Square D, Cutler-Hammer, Westinghouse, and Perigrip Benefits • Installation cost savings • S ingle source brake supplier • Replace obsolete brakes without structural rework CUSTOM ENGINEERED BRAKES Features and Benefits • Stainless steel frame hardware and links • Nitride heat treat corrosion protection • Special mountings (wall, ceiling) • Manual brakes BRAKES
BRAKES BRAKE ACCESSORIES Rectifiers/Controllers • Converts AC power to DC power for use with certain types of 200S General Purpose Industrial Brakes and 300M AIST Mill Duty Brakes • Available in enclosures or on backing plates for panel mounting Brake Wheels • Manufactured from ductile-iron alloy • Completely machined to provide proper balance at normal operating speeds • Available for 200S General Purpose Industrial Brakes and 300M AIST Mill Duty Brakes Couplings • Eliminate the need for expensive double
COLLISION AVOIDANCE SYSTEMS REFLX® DISTANCE DETECTION AND COLLISION AVOIDANCE SYSTEMS Features and Benefits • L imits potential for crane-to-crane or crane-to-object collisions • Helps keep your overhead material handling system up and running safely • Ideal for use with all types of adjustable frequency drives and stepped controls • Use the reliable, solid-state control board as a stand-alone unit, or remove from its enclosure and mount as one piece on an existing control sub-panel • 220 Vac, 250 Vdc,
CONTROL PRODUCTS IMPULSE®•G+ SERIES 4 ADJUSTABLE FREQUENCY CRANE CONTROLS • Magnetek’s new IMPULSE•G+ Series 4 drives continue our tradition of providing the most reliable and cost-effective adjustable frequency crane controls available • Industry-leading safety and performance features combine with our superior application expertise to provide unmatched performance for your material handling system • Backed by our industry-leading three-year warranty • Can be used as an open-loop vector or V/F crane contro
CONTROL PRODUCTS IMPULSE®•VG+ SERIES 4 ADJUSTABLE FREQUENCY CRANE CONTROLS • Magnetek’s new IMPULSE•VG+ Series 4 drives continue our tradition of providing the most reliable and cost-effective adjustable frequency crane controls available • Industry-leading safety and performance features combine with our superior application expertise to provide unmatched performance for your material handling system • Backed by our industry-leading three-year warranty • Can be used as a closed-loop flux vector crane contr
CONTROL PRODUCTS IMPULSE®•G+ MINI ADJUSTABLE FREQUENCY CRANE CONTROLS • Low horsepower IMPULSE•G+ Mini is our easiest to program drive to-date, with X-Press Programming™ providing fast set-up in minutes to get your drive up and running quickly • Compact design permits the use of smaller control enclosures, reducing overall cost of an installation • Expands application opportunities on smaller cranes, hoists, trolleys, and monorail carriers • Features an expanded HP range and an identical dimensional footpri
CONTROL PRODUCTS IMPULSE®•T ADJUSTABLE FREQUENCY CRANE CONTROLS • IMPULSE•T makes drive programming so easy you can get cranes up and running in a few simple steps.
CONTROL PRODUCTS IMPULSE®•D+ AC LINE REGENERATIVE SYSTEM • IMPULSE•D+ system is a high-performance regeneration unit in a chassis drive layout • Units take surplus regenerative energy from the motor and return it to the AC power source, reducing total energy consumption and improving energy efficiency • Combining with IMPULSE®•G+ or VG+ Series 4 Adjustable Frequency Drives provide the most energy efficient, durable, and feature-rich crane control system available Features and Benefits • Active Front End te
CONTROL PRODUCTS OMNIPULSE™ DDC DIGITAL DC DRIVES Features and Benefits • State-of-the-art energy efficient OmniPulse DDC Drives improve the performance and reliability of your DC operated crane or hoist, while minimizing downtime, maintenance expenses and energy costs • T he smart choice in crane control that will pay dividends and provide your facility with a competitive advantage for years to come • Semiconductor technology provides better control of motor speed and torque than costly, inefficient DCCP
CONTROL PRODUCTS OMNIPULSE™ DSD DC CONTROL Features and Benefits • OmniPulse DSD is a state-of-the-art, fully programmable DC digital drive designed for crane, hoist, and heavy moveable structure applications • Developed specifically to control DC shunt wound motors for bridges, trolleys and hoists • Improves performance, safety, and reliability in your facility while minimizing downtime • Easy to install and program • Solid-state operation requires less maintenance • Patented microp
CONTROL PRODUCTS & CONTROL PANELS RADIO DRIVE SERIAL INTERFACE (RDSI) • Enables two-way communication directly from the drive, allowing you to access diagnostic and troubleshooting information such as drive status, output frequency, and load weight on the ground • Displays feedback parameters directly from the drive, allowing you to access diagnostic and troubleshooting information such as drive status, output frequency, and load weight on the ground • Automatically detects drive types, allowing you to comm
CONTROL PANELS CUSTOM COMPLETE CONTROL PANELS Features and Benefits • C ustom panels with IMPULSE®, OmniPulse™, and MagnePulse™ controls provide the ultimate solution for overhead material handling • Built and designed to your specifications, these panels include all the standard features of our pre-engineered panels and can be customized with an unlimited number of configurations, components, and accessories • Our skilled engineering staff provides technical support and overhead handling expertise • Pair
DRIVE SUPPORT TOOLS IMPULSE®•LINK 4.1 WIRELESS DIAGNOSTIC SYSTEM (WDS) Features and Benefits • Windows-based interactive drive software and hardware package designed to enhance productivity by allowing you to efficiently program, monitor and troubleshoot multiple drives from a remote location •W DS bridges the gap between your facility’s IMPULSE, OmniPulse™, or MagnePulse™ drives and Ethernet network • Advanced diagnostics provide critical information to keep your system up and running.
CUSTOM SOFTWARE FOOTBRAKE/STATIC STEPLESS SIMULATION CUSTOM SOFTWARE Features and Benefits • Designed for IMPULSE®•VG+ Series 4 drives used on traverse motions to provide an effective means to slow or stop the motion of the bridge or trolley • Eliminates current spikes and excess mechanical torque/stress on the drive train, and allows quick but smooth starting or changing of direction • Improved torque control ensures a smooth transition from coasting to slowing down and is non-destructive to the controls o
CUSTOM SOFTWARE DRIVE SYNCHRONIZATION CUSTOM SOFTWARE Features and Benefits •A llows you to synchronize multiple IMPULSE®•VG+ Series 4 Drives • The “slave" drives utilize an encoder option board with two encoder inputs, and monitors both its own encoder feedback AND the “master’s" encoder feedback, while also sending timing status information back to the master • The slave drive compensates for any position errors by adjusting its motor speed, resulting in near-perfect alignment between the master and sla
MOTORS BLACK MAX® MOTORS Features and Benefits • Economical model designed to meet the needs of more common crane applications • Capable of a 1000:1 speed range • ½ to 50 HP • Suitable for CMAA Class A through E − ½ to 30 HP Cont. duty − ½ to 50 HP 60 Min.
PENDANT SYSTEMS SBI PENDANT PUSHBUTTON STATION • Lightweight, ergonomic design allows the SBI Pendant to deliver optimum control and performance with less effort and fatigue than traditional pendants • Available in 2-12 button configurations, momentary or maintained on/off, and with a variety of options and accessories Features and Benefits • Slim line pendant provides optimum control and performance, resting comfortably in the palm of your hand and most weighing less than two pounds • External
PENDANT SYSTEMS SBP2® PENDANT PUSHBUTTON STATIONS Features and Benefits • Lightweight, ergonomic design rests comfortably in the palm of your hand • Provides optimum control and performance with less effort and fatigue than traditional pendants • High-impact resistant, watertight enclosure designed to survive even the most brutal environments • SBP2 housing more chemically resistant than SBP housing • Housing designed for ease of wiring • Tandem design available for malfunction/ automatio
POWER DELIVERY SYSTEMS ELECTROBAR® 8-BAR CONDUCTOR BAR SYSTEM •P ractical, proven, and economical way to deliver electricity to overhead cranes, hoists, monorails, and other types of moving equipment • Traditional figure 8 design allows you to use it interchangeably with common bottom-entry 8-bar systems • Single and tandem collector assemblies available for smooth, continuous contact along straight runways or curved applications • Vertical or horizontal mounting configurations • 70% duty cycle (84 second
POWER DELIVERY SYSTEMS ELECTROBAR ELITE® ENCLOSED CONDUCTOR BAR SYSTEM Features and Benefits • O ur most advanced and versatile conductor bar system • C ompact lightweight enclosed design allows you to safely put the conductors in a small dimensional package compared to traditional 8-Bar • Ideally suited for low headroom applications, preventing incidental contact with a power conductor bar • Low friction makes it suitable for workstation bridge cranes • Curved line elements available from 32" radiu
POWER DELIVERY SYSTEMS POWER DELIVERY SYSTEMS FESTOON SYSTEM DIAGRAM 1. Track Sections and Cross Arm Brackets 8. End Cap 2. Joint Assembly 9. Tow Trolley 3. Tow Arm 10. Control Box Trolley 4. Cross Arm Mounting Bracket 11. Trolley 5. Hanger Assembly − Standard Profile − Low Profile − C-Hanger 12. Junction Boxes/Terminal Strips 13. Cable Grips 14. Festoon Cable 6. End Cable Clamp 7. End Stop 26 www.magnetekmh.
POWER DELIVERY SYSTEMS C-TRACK FESTOON SYSTEMS • Galvanized standard and heavy-duty C-Track – 10', 20' length • Stainless steel standard duty C-Track – 10', 20' length • Single and double flat cable trolley saddles – 150 lb. capacity each • Single and double round cable trolley saddles – 150 lb.
POWER DELIVERY SYSTEMS HEAVY-DUTY ALUMINUM FESTOON SYSTEMS • Heavy-duty aluminum extruded track – 10', 20' length • Track sections may be formed to a minimum 36" radius •S ingle and double flat cable trolley saddles – 150 lb. capacity each • Single and double round cable trolley saddles – 150 lb.
POWER DELIVERY SYSTEMS MILL DUTY & MARINE TERMINAL I-BEAM FESTOON TROLLEYS Features and Benefits • Standard 4" diameter trolley wheel • Capacity of flanged main wheel trolley − 800 lbs. @ 400 ft. /min. − 600 lbs. @ 600 ft. /min. • Capacity of non-flanged trolley wheel (with side guide rollers) − 1,000 lbs. @ 400 ft. /min. − 800 lbs. @ 600 ft. /min.
RADIOS − CRANE & HOIST TELEMOTIVE telePENDANT™ TRANSMITTER •A vailable in up to three motions with six auxiliary functions or five motions with four auxiliary functions using A & B select • I ncludes traditional pendant-style pushbutton station switches, rating for a million plus operations, and two and three-speed designs Features and Benefits •R ugged and chemically resistant transmitter case has the ability to withstand shock and harsh environments •S tores four complete system configurations, eli
RADIOS − CRANE & HOIST TELEMOTIVE FLEX VUE® TRANSMITTER • Available with several options to meet the needs of a variety of applications and industries •C hoose between 4, 8, and 12 two-step or stepless button configurations with accurate and smooth operation Features and Benefits • Available two-way radio frequency for applications requiring feedback of machine parameters, alarms, and command confirmation • R ugged, super tough nylon housing withstands shock, water, heat, and harsh environments • Hig
RADIOS − CRANE & HOIST ENRANGE™ FLEX EX TRANSMITTER •A vailable with several options to meet the needs of a variety of applications and industries •C hoose between 4, 6, 8, and 12 button style options to with accurate and smooth operation Features and Benefits •A dvanced synthesized RF controls with 62 user-programmable channels add flexibility to frequency management in the field •D urable enclosures are made from industrial-strength nylon and fiberglass composite materials •A dvanced microproce
RADIOS − CRANE & HOIST ENRANGE™ 300T TRANSMITTER •A vailable with several options to meet the needs of a variety of applications and industries •A cost-effective, high performance package provides remote crane controls with easy operations and maintenance Features and Benefits • F ully proportional/programmable versions are available for stepless 3-5 speed applications • L arge buttons make this unit popular for applications that require the operators to wear gloves •E ach motion can be configured
RADIOS − CRANE & HOIST TELEMOTIVE MLTX2™ TRANSMITTER •A vailable with several customizable options to provide the ideal solution for a variety of applications and industries •O ffers plug-and-play control packages designed specifically for your material handling equipment, manufactured and tested on our panel assembly line Features and Benefits •R ugged, super-tough nylon housing is made to withstand shock and NEMA 4 (IP66) sealing can easily endure harsh, industrial environments •G raphic display
RADIOS − CRANE & HOIST TELEMOTIVE MLTX™ TRANSMITTER • Available with many customizable options to meet the needs of a variety of applications and industries • Lightweight, ergonomically designed contoured case incorporates the latest polymer technology Features and Benefits • Rugged, super-tough nylon housing is made to withstand shock and NEMA 4 (IP66) sealing can easily endure harsh, industrial environments • One of the longest lasting batteries in the industry is designed to minimize power consumpti
RADIOS − CRANE & HOIST TELEMOTIVE PENDANT–STYLE TRANSMITTER • T he Pendant-Style series offers a wide selection of industrial grade transmitters to meet your application in the most economical fashion •A vailable in three or five motions with A, A+B, or B selector providing you with flexibility •P endant-Style transmitter can control the heaviest crane to the lightest hoist or monorail system Features and Benefits •D esigned to minimize power consumption, providing one of the longest life batteries
RADIOS − MOBILE HYDRAULIC ENRANGE FLEX VUE® TRANSMITTER • Available with several options to meet the needs of a variety of applications and industries • Choose between 4, 8, and 12 two-step or proportional button configurations with accurate and smooth operation Features and Benefits • Available two-way RF for applications requiring feedback of machine parameters, alarms, and command confirmation • Rugged, super tough nylon housing withstands shock, water, heat, and harsh environments • High resolution col
RADIOS − MOBILE HYDRAULIC ENRANGE FLEX PRO™ TETHERED CAN-BUS CONROLLER • Incorporates the latest in proportional control technology in a lightweight, comfortably contoured, yet durable case • Provides “one-handed” operation, useful for applications that require operators to assist in control of the machine Features and Benefits • Choose 8 or 12 proportional button configurations with precise control for smooth operation • Adjustable speed control −four mode settings (25%, 50%, 75%, and 100% output) provide
RADIOS − MOBILE HYDRAULIC ENRANGE™ XLTX TRANSMITTER • Available with several options to meet the needs of a variety of applications and industries • Graphic display with system diagnostics including battery life, signal strength, and warning symbols Features and Benefits • Incorporates the latest electronic technology in a lightweight, comfortably contoured, durable case • Rugged, super-tough nylon housing is made to withstand shock and NEMA 4 (IP66) sealing can easily endure harsh, industrial environments
RADIOS − MOBILE HYDRAULIC ENRANGE™ MLTX TRANSMITTER • Available with many customizable options to meet the needs of a variety of applications and industries • Dual access code system provides peace-of-mind because the signal only operates the intended equipment Features and Benefits • Lightweight, ergonomically designed contoured case incorporates the latest polymer technology • Rugged, super-tough nylon housing is made to withstand shock and NEMA 4 (IP66) sealing can easily endure harsh, industrial enviro
RADIOS − MOBILE HYDRAULIC ENRANGE™ MBT TRANSMITTER • Incorporates the latest electronic technology to meet the needs of a variety of applications and industries • Offers control capability similar to larger bellybox transmitters, including proportional thumbsticks, toggle switches, potentiometers, graphic display, two-way feedback, and FHSS RF Features and Benefits • Optional Radio Control Programmer (RCP) connects via USB, allowing you to program settings from your Windows PC • One of the longest lasting
RECEIVERS ENRANGE™ MHR RADIO CONTROLLER • Combines components of a radio receiver and hydraulic controller into a convenient single unit • Includes an informative LCD graphic display for viewing system settings and machine functions Features and Benefits • Rugged, waterproof design is resistant to shock and vibration, making it ideal for outdoor use and harsh environments • User interface features fully sealed pushbuttons for menu navigation and modifying system settings in the field • Two-way feedback pro
RECEIVERS ENRANGE™ FLEX 4/6 EX RECEIVER OUTPUTS 8 motion relays, 1 MLC relay, 1 horn relay INPUTS NA COMMUNICATION NA FREQUENCIES Part 15 License Free 433-440MHz Part 90 Licensed NA Two-way NA OPERATING RANGE Up to 300 feet DIAGNOSTICS On-board diagnostics with LED indicators for receiver status INPUT VOLTAGE 105-480 Vac, 9-36 Vdc COMPATIBLE WITH Flex EX RECEIVERS ENRANGE™ FLEX 8/12 EX RECEIVER OUTPUTS Up to 24 motion relays, 1 MLC relay, 1 horn relay INPUTS NA COMMUNICATION NA
RECEIVERS ENRANGE WIC-2402™ WIRELESS CAN MODULE OUTPUTS 4 digital on/off INPUTS NA COMMUNICATION 1 CAN-bus FREQUENCIES Part 15 License Free 2.4-2.5GHz Part 90 Licensed NA Two-way NA OPERATING RANGE Up to 2000 feet DIAGNOSTICS On-board diagnostics with LED indicators for receiver status RECEIVERS INPUT VOLTAGE 12-24 Vdc nominal (6-36 Vdc max) ENRANGE™ CAN-2 RECEIVER OUTPUTS 2 digital Used for machine stop COMMUNICATION 1 CAN-BUS FREQUENCIES Part 15 License Free 430-439.8MHz, 2.
RECEIVERS ENRANGE™ CAN-6 RECEIVER OUTPUTS 8 digital on/off and 8 0-10 Vdc analog INPUTS NA COMMUNICATION 1 CAN-bus FREQUENCIES Part 15 License Free 430-440MHz, 902-928MHz Part 90 Licensed NA Two-way Available upon request OPERATING RANGE Up to 300 feet DIAGNOSTICS On-board diagnostics with LED indicators for receiver status INPUT VOLTAGE 9-36 Vdc COMPATIBLE WITH XLTX, MLTX, MBT, PGT, Flex EX, Flex Pro ENRANGE™ CAN-R1 RECEIVER OUTPUTS 4 digital on/off INPUTS 4 analog or digital CO
RECEIVERS CAN-M1 EXPANSION MODULE OUTPUTS 8 Solid state digital outputs 2.
RECEIVERS RADIO CONTROL PROGRAMMER OPTION (RCP) Features and Benefits • User-friendly, interactive Radio Control Programmer software allows you to program systems settings from your Windows PC • Enables creation and saving of system configurations for future use and transferable configurations among multiple radio control products • RCP packages include a USB Drive, activation code, USB cable, and User’s Guide • Compatible with the following products: − Telemotive telePendant™ Transmitter − Telemotive teleP
ENGINEERED SYSTEMS ENGINEERED SYSTEMS • The Engineered Systems Group is dedicated to helping our customers achieve maximum performance from their material handling equipment.
ENGINEERED SYSTEMS ENGINEERED CONTROL SYSTEMS Magnetek helps you identify, select, and implement the best and most cost-effective mix of motion control technologies and leading edge product offerings to meet your application needs and provide future flexibility for your material handling systems.
ENGINEERED SYSTEMS ENGINEERING DESIGN AND PLC/PC PROGRAM DEVELOPMENT A team of engineers trained and experienced in circuit design, packaging of equipment, PLC, PC, and HMI program development will design your engineered system per the application requirements.
ENGINEERED SYSTEMS AUTOMATED DRY-DOCK BOAT STORAGE/RETRIEVAL SYSTEM BRIDGE CRANE Products • Electromotive Systems IMPULSE ®•G+/VG+ Series 2 Adjustable Frequency Drives • Telemotive telePilot Radio Remote Controls • Magnetek Festoon Systems • Allen-Bradley PLC and HMI • Laser Positioning Systems • RFID technology The System AUTOMATED LUMBER HANDLING CRANE SYSTEM ENGINEERED SYSTEMS An automated dry dock boat storage system utilizing an overhead bridge crane.
ENGINEERED SYSTEMS AUTOMATED MILL ROLL HANDLING SYSTEM Products • E lectromotive Systems IMPULSE ®•G+ Series 2 Adjustable Frequency Drives • S BP2 ® Pushbutton Pendant Stations • M agnetek Festoon Systems • Wireless Ethernet Communication • A llen-Bradley PLCs • I ndustrial PCs • R FID Technology • L aser Positioning The System ENGINEERED SYSTEMS Two fully automated bridge cranes and two automated transfer cars.
ENGINEERED SYSTEMS AUTOMATED ENGINE PAINT LINE MONORAIL SYSTEM MONORAIL SYSTEMS Products • E lectromotive Systems IMPULSE ®•VG+/G+ Series 3 Adjustable Frequency Drives • PulseStar Radio Remote Controls (workstation operation) • SBP2® Pushbutton Pendant Stations (maintenance control) • FABA ® Conductor Bar • Allen-Bradley PLCs and HMIs • Wireless Data Communication The System AUTOMATED WHEEL AND STRUT PAINT LINE MONORAIL SYSTEM Products • E lectromotive Systems IMPULSE ®•P3 Series 2 Adjustab
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