ISSUE 1 2015 YOUR ONE-STOP SOURCE FOR MATERIAL HANDLING CONTROL SOLUTIONS SPOTLIGHT ON SUCCESS HOOVER DAM CRANE CONTROL MODERNIZATION PROJECT Magnetek s Material Handling team recently spent time working inside the Hoover Dam s concrete structure alongside Precision Crane & Hoist Services of Nevada to modernize the facility s aging AC static crane controls with state-of-the-art control technology developed by Magnetek. The Hoover Dam has two power plant wings, one located in Nevada and one located in Arizona. Each wing is 650 feet long and rises nearly 300 feet above the foundation of the power plant. Two 300-ton cranes are located inside each power plant wing and are used to move and maintain the 17 main vertical hydraulic turbines housed within the wings. The Hoover Dam Power Plant, one of the United States largest hydroelectric installations, generates approximately four billion kilowatt-hours of hydroelectric power on average each year, enough to serve 1.3 million people in Arizona, Nevada, and California. Magnetek controls are scheduled to be retrofitted on each of the four 300-ton cranes over a seven-month period which began in December 2014. The new crane control systems will utilize Magnetek s technologically advanced drives and radio controls, providing crane operators at the Hoover Dam Power Plant with improved productivity, safety, and reliability. 1
HAZARDOUS LOCATION RADIOS XLTX AND MLTX2 NOW AVAILABLE WITH GRAPHIC DISPLAY Magnetek s ergonomic, easy-to-use ATEX and IECEx certified XLTX and MLTX2 transmitters are now available with graphic displays. Improving operator safety, communication, and diagnostics, integrated graphic displays keep operators informed of system status at all times and simplify the configuration of access codes, channels, and other system settings. The graphic display is standard on XLTX transmitters and optional on MLTX2 transmitters. Both also now offer unlicensed 900 MHz frequency with the IECEx certification. Graphic Display Communicates System Diagnostics Including: Battery Life Machine Diagnostic Information Signal Strength Real Time Machine Status Fault and Alarm Status Required in the European Union, ATEX certifies Magnetek s radio remote controls are approved for use in potentially explosive areas with flammable gases or vapors. IECEx certifies that Magnetek s radio remote controls conform to international safety standards for environments where a potential exists for explosions. XLTX and MLTX2 transmitters are certified for use in EX Zone 0, Zone 1, and Zone 2 environments that may involve potentially explosive situations due to the production or release of gases or vapors. 2
REFLX 45 & LASERGUARD2 JOIN THE COLLISION AVOIDANCE FAMILY The ReFlx 45 and LaserGuard 2 systems join the ReFlx 120 as options to enhance the performance of overhead material handling systems by preventing crane-to-crane or crane-to-end-stop collisions. Avoiding collisions results in increased operator safety and reduced maintenance costs. New collision avoidance system options include an array of functionalities, sizes, and price points to complement Magnetek s innovative power control and delivery systems and solutions. The ReFlx 45 is ideal for a single stop event with one contact point. All electronic components are built into the IP67-rated housing, enabling easy installation on overhead material handling applications. ReFlx 45 has a detection range of 3-45 feet, and the system includes a sensor, reflector, and sensor bracket. The next generation LaserGuard2 is the most technologically advanced system available, able to detect from eight inches to 150 feet. It uses self-monitoring optical lasers to check a crane s position and the multi-distance detection feature is flexible enough to manage crane-to-crane and crane-to-wall operation. The LaserGuard2 system includes a laser support unit, reflector, laser, mounting bracket, and sensor cable. The ReFlx 120 system, which features a reliable, solidstate control board in a small, easy-to-install enclosure, completes the collision avoidance family and includes a sensor cable, reflector, and controller. PATENTS AWARDED FOR IMPULSE VG+ ADJUSTABLE FREQUENCY DRIVE TECHNOLOGY Magnetek was awarded two patents by the United States Patent and Trademark Office for features on the IMPULSE VG+ Adjustable Frequency Drive. Protected by Patent Nos. 8,669,724 and 8,686,670, the new technologies, Adaptive Ultra-Lift and Brake Test, respectively, were issued for methods and apparatuses for load dependent speed control of a motor, enabling earlier preventative maintenance, and for calibrating and testing brake holding torque, which enhances safety. Adaptive Ultra-Lift is ideal for repetitive, high-cycle count applications that demand maximum speed such as in the lumber, paper, or marine terminal industries and especially in applications where rope overwraps on the drum. Continually measuring torque and regulating rotational speed throughout a run reduces cycle times, increases process speed, and improves productivity. The Brake Test feature on Magnetek s IMPULSE VG+ drives determines the condition of a brake so preventative maintenance can be performed or brake accessories can be replaced. Brake Test verifies brake torque with the press of a button, capturing breakaway torque with a monitor parameter on the keypad. If the brake slips, Brake Test will capture the breakaway torque information and present it on the display. Periodic measurement of brake performance with Brake Test can help prevent problems such as load drops resulting from weakened springs or worn brake pads, thereby improving safety. 3
This dredge is light-years ahead of the competition from both a technological and environmental standpoint. TDC CRANES DREDGER PROJECT Over the last two years, Magnetek has worked closely with Canada-based TDC Cranes Ltd. to engineer the most technologically advanced and highest producing dredge crane currently operating in North America. From very early in the process, Magnetek was an essential part of our team for this project, said Rick Gillespie, president of TDC Cranes Ltd. We weren t interested in people that were just selling components. We needed a company with the ability to provide complete system solutions that included both drives and the custom software required for a project of this scale. The heart of the massive dredger s precision crane control system features two IMPULSE G+ and VG+ Series 4 Adjustable Frequency Drives with state-of-the-art Bucket Control Custom Software controlling two Blue Max Motors with advanced safety and control features for the dredging system. Developed by Magnetek, the control systems eliminate the need for more traditional hydraulic systems that have the potential to leak, creating environmental risks. In addition, the adjustable frequency drives provide industry-leading precision and control and extend the service life of the crane from 20,000 hours to more than 200,000 hours. IMPULSE G+/VG+ Series 4 control systems eliminate the need for foot pedals and mechanical levers, meaning that operators can work for extended periods of time without suffering from fatigue. It takes an enormous amount of power to operate the dredge s massive 60-yard bucket, which has the ability to fill a 5,000 cubic-yard scow in just over two hours nearly three times 4
If we have a mission-critical machine, we use Magnetek. ~ Rick Gillespie faster than any other crane dredge in North America. Power for the vessel is provided by twin Caterpillar diesel generators that produce an impressive 1,600 ekw of power. The dredge crane features 200,000 pounds of line pull per hoist with a 250 foot-per-minute rating, and a 75-foot operating radius. In order to meet the demands of today s precision dredging projects, the crane can be equipped with either a 60-yard bucket for trimming or a 28-yard bucket for heavy digging. With a crane of this size, the notion that it can be easy to operate may seem hard to imagine. However, that is where many of its high-tech features and advanced bucket control software options come into play. The drives custom software allows the operator to automatically coordinate the winches, auto-close, auto-open, and cinch control. This means that as the closed bucket hauls up tons of sludge, Magnetek s innovative, custom software solutions automatically monitor and adjust the closing winch 60 times per second to ensure the bucket remains closed even when the winch is inactive. The vessel took its maiden voyage in October 2013 to begin maintenance dredging in both Norwalk and New Haven, Connecticut, harbors for the U.S. Army Corps of Engineers. Once these projects were completed, the dredge set sail for Portland, Maine, where it began the first maintenance dredging on the Portland Harbor in nearly two decades. Based on the success of this project, TDC Cranes and Magnetek recently partnered again to build a smaller, pier-mounted crane rated for 100,000 lbs. duty cycle at 100 ft. radius and featuring similar advanced control technology. According to Rick Gillespie, the future of duty cycle cranes is AC electric. 5
DYNAMIC BRAKING UNITS OFFER ADVANCED FEATURES Magnetek s new CDBR-D Dynamic Braking Units work in concert with our Dynamic Braking Resistors to dissipate excess energy produced by motors controlled by IMPULSE Variable Frequency Drives. CDBR-D Dynamic Braking Units provide advanced troubleshooting features including: Resistor (output) short protection with an independent fault output Additional diagnostic LEDs Ratings to 60 C ambient operating temperature More available voltage threshold settings These CDBR-D Dynamic Braking Units require up to 40% less panel space than previous generation CDBR-B models. This can reduce required panel and enclosure size when space is at a premium. THE LATEST CONTROL TECHNOLOGY IN THE PALM OF YOUR HAND While retaining many of the capabilities found in Magnetek s full size wireless controls, this new line of lightweight miniature transmitters provides an effective yet economical solution for controlling a variety of material handling applications. Users can choose from a range of products to get the exact functionality, size, and style that fits their application needs. The Flex Mini, a low-cost, easy-to-configure transmitter, is an ideal solution for applications that require simple control operations. It features up to eight pushbuttons for on/off control and has a new pairing feature that helps increase up time. The Flex Mini fits comfortably in the palm of an operator s hand, preventing fatigue during use, and its compact design enables one-handed operation, freeing operators to assist with other tasks. The ergonomically styled Mini-MBT transmitter is one of the smallest and lightest bellybox controls available today. While the compact Mini-MBT fits easily in an operator s hands, it offers many of the same capabilities as larger bellybox transmitters including toggle switches, potentiometers, graphic display, two-way feedback, and a fully proportional control option. 6
NEXT GENERATION FLEX M RECEIVER OFFERS SAFETY AND FUNCTIONALITY The Flex M Receiver, successfully operating in crane and hoist applications for over 13 years, has a new, next generation operating platform developed to meet UL, cul, and CE requirements. With UL and cul markings, Flex M may be used in applications requiring the marks without the need for intermediate relays or additional hardware that increases the cost and complexity of the system. CE marking permits use of the Flex M in applications in the European Union. NEW FEATURES Mainline (Machine Stop) relays included on the CPU eliminate the need for an additional relay module, reducing overall cost and providing a PL d rated machine stop. PL d rated machine stop conforms to the safety standard EN 13849, detects internal faults, and ensures that if there is an error within the receiver, it will go to a safe mode to prevent unsafe operating conditions. Optional external display shows receiver status while retaining the functionality of communicating receiver status to a Magnetek transmitter with a display. Infrared (IR) Pairing is a simple matching method, available on the MLTX2, XLTX, MBT, PGT, Mini-MBT, Mini-PGT, and Flex VUE transmitters, that pairs a transmitter and receiver through an IR interface in order to control that specific receiver. This allows receivers and transmitters to exchange information required to communicate via RF without the need for a menu system or RCP. RCP Communication allows operators to program system settings from a Windows PC, which enables saving system configurations that can quickly bring spare units into service along with quick modification to basic configuration parameters. DID YOU KNOW? INTERACTIVE PRODUCT GUIDE VIDEO LIBRARY Magnetek s interactive Material Handling Product Guide is now available at www.magnetekmh.com/productguide. Magnetek offers an extensive array of digital drives, radio controls, inverter duty motors, AC line regenerative systems, braking and collision avoidance systems, and a whole lot more. This easy-to-use Material Handling Product Guide provides an in-depth overview of our control and power delivery products, including brief product overviews, important features and benefits, and technical specifications. The guide operates on all mobile devices with an internet connection and can be downloaded as a file into the ibooks application on IOS devices. Visit Magnetek s new Videos page on our website at www.magnetekmh.com/videos. You can access the video page through Magnetek s Material Handling and Mobile Hydraulic websites through the navigation dropdown menus under Support. This new web page acts as a video library for our innovative power control and delivery products and will help you stay up to date with the latest how-to videos and product updates. The videos included on the new page have existed and still exist on individual product pages and on Magnetek s YouTube channel but are now consolidated for your convenience. Any future Magnetekrelated videos can easily be found on this page as well. 7
N49 W13650 Campbell Drive Menomonee Falls, WI 53051 INSIDE THIS ISSUE Hoover Dam Crane Control Modernization Project Hazardous Location Radios Now Available with Graphic Display ReFlx 45 and LaserGuard 2 Join Collision Avoidance Family Patents Awarded for IMPULSE VG+ Adjustable Frequency Drive Technology TDC Cranes Dredger Project Dynamic Braking Units Offer Advanced Features The Latest Control Technology in the Palm of Your Hand Next Generation Flex M Receiver Offers Safety and Functionality Did You Know? ISSUE 1 2015 YOUR ONE-STOP SOURCE FOR MATERIAL HANDLING CONTROL SOLUTIONS EVENTS 2015 CALENDAR 22nd Annual AIST Symposium Speakership Advanced Safety Technology for Hot Metal Cranes, Jon Walters June 7-9 Pittsburgh, PA IMPULSE Series 4 Training Join Magnetek for a comprehensive, in-house technical training program covering the IMPULSE G+ Mini and IMPULSE G+/VG+ Series 4 Drives. Training includes classroom instruction and hands-on experience reviewing basic drive theory and how to s, including programming, maintenance, and troubleshooting of adjustable frequency crane controls for overhead material handling applications. September 15-17 December 8-10 Evolution is published by Magnetek Material Handling. Questions and comments can be directed to Evolution, Marketing Communications: N50 W13775 Overview Drive Menomonee Falls, WI 53051 2015 Magnetek Material Handling MH401_Evolution 2015 Issue 1