A Resource Library of Our Products and Services

Electrification Products for Cranes

Milwaukee Crane has the right electrification product for you

Milwaukee Crane has world class crane and hoist electrification systems for new crane systems, crane rebuilds, crane retrofits and crane service.

The most frequently installed and serviced types of electrification are:

• Crane Bridge
• Cable Reel
• Shielded Bar
• Festoon Cable

• Monorail and Runway
• Cable Reel
• Shielded Bar
• Festoon Cable

Milwaukee Crane offers these fine product lines for your electrification needs:

• Duct-O-Wire
• Electromotive
• Insul-8

You can view detailed information at the above links.

Please contact Milwaukee Crane's expert staff for applications assistance with electrification products.

Electromotive Crane Components

Crane Controls, Electrification, Inverter Drives and More

Electromotive Systems, a Magnetek company, is the world's leading designer and manufacturer of electrification and control products for the overhead material handling industry.

• Electromotive Systems IMPULSE� Series crane controls have a proven track record of providing unmatched performance and reliability to the overhead material handling industry.
• Electrification Electromotive Systems is an industry leader in providing precision electrification products for overhead material handling equipment.
• Engineered Systems Electromotive Systems offers a broad range of control, application & system solutions for overhead material handling.
• Contract Services Electromotive contract services offer the facilities and know-how to cost-effectively manufacture control systems to meet your exact specifications.

See more information on

Electromotive products:

Motion Controls

A combination of extensive application experience and leading-edge products provides the ultimate solution for overhead motion control.

Remote Radio Controls

PulseStar� Remote Radio Controls set a whole new standard in radio remote crane controls.

Electrification

Electromotive Systems is an industry leader in providing precision electrification products for overhead material handling equipment.

Please contact Milwaukee Crane's expert staff for applications assistance with Electromotive products, Engineered Systems and Contract Services.

Motion Controls

IMPULSE� AC Crane Controls

Electromotive Systems IMPULSE� Series crane controls have a proven track record of providing unmatched performance and reliability to the overhead material handling industry.

OmniPulse™ DC Digital Crane Controls

Electromotive Systems introduces OmniPulse Digital Crane Controls, the only microprocess controlled DC drive designed to work specific with a DC power input source.

MAC™•2000

Electromotive Systems introduces MAC™•2000, a reduced voltage soft start for applications needing cost-efficient motor control.

TCONTROLS�

TCONTROLS� Complete Crane Control Panels feature all the components needed to provide complete motor control for bridge, trolley, hoisting or combined overhead crane motions.

ReFlx™

The Electromotive Systems' ReFlx™ 120 and 120 "Plus" distance detection and collision avoidance systems are designed with reliability and economy in mind.

Motors

Electromotive Systems' inverter duty motors have been designed to meet the demands of crane/hoist applications, where premium construction and performance are a must.

Radio Controls

PulseStar� Systems

Electromotive Systems has achieved a whole new level of performance, reliability and value with our technologically advanced line of PulseStar� Remote Crane Controls.

Transmitters

Lightweight, durable transmitters for PulseStar� Remote Crane Controls.

Electrification

Electromotive Festoon Systems and Cable

ELECTROMOTIVE™ Festoon Systems and Cable provide an efficient method of delivering power and control to overhead material handling equipment.   

SBP Pendant Pushbutton Stations

Electromotive Systems' SBP� Pendant Pushbutton Stations provide optimum control and performance with less effort and fatigue than traditional pendants.

SBP2 Pendant Push-button Stations

The new Electromotive Systems' SBP2 features an ergonomic design that delivers improved control, performance and more operator comfort.

ELECTROBAR�, ELECTROBAR ELITE�, ELECTROBAR� FS And FABA� Enclosed Conductor Bar Systems

ELECTROBAR�, ELECTROBAR ELITE�, ELECTROBAR� FS And FABA� Enclosed Conductor Bar Systems provide an array of options and accessories for the electrification of overhead material handling equipment.

Please contact the experts at Milwaukee Crane for assistance with Electromotive products and services.

IMPULSE��P3 Series 2 AC Crane Control

The Electromotive Systems IMPULSE��P3 Series 2 crane control gives operators total command over crane and hoist movements.

 

IMPULSE��G+ Series 2 AC Crane Control 

Electromotive Systems IMPULSE��G+ Series 2 crane controls have a proven track record of providing unmatched performance and reliability in the overhead material handling industry.

IMPULSE��VG+ Series 2 AC Crane Control 

Featuring our exclusive crane and hoist software, IMPULSE��VG+ Series 2 third generation controls offer many features designed for ease of use and enhanced safety.

MAC��2000

Motor Acceleration Control

A reduced voltage soft start for applications needing cost-efficient motor control.

Versatility, reliability and value are the three words that best describe Electromotive Systems' MAC��2000 motor acceleration control.

Versatile

A common unit can be utilized for single- and two-speed applications in the 230V/460V design for up to 15.2 amps. The 575V model is similarly designed with single- and two-speed capability in a common unit for up to 15.2 amps.

Reliable

MAC��2000 has been designed specifically to recognize the high duty cycle start, stop and jogging conditions that are associated with overhead material handling applications.

Value

The versatile design of this motor acceleration control reduces the need to maintain inventories of units with various voltage and speed capabilities as is seen with other soft start manufacturers. In addition, this unit has been produced to recognize the needs of our customers for a low cost control device for less sophisticated applications.

Check out the additional features included in our MAC��2000 control and include it as part of your next crane control solution.

Quality Design and Versatile Features to Keep You Up and Running

• Adjustable starting torque and acceleration time.
• Compact size.
• Voltage ramp reset.
• Phase loss protection.
• Rugged construction for mounting on traveling cranes and monorails.
• CMAA Class "D" Service.
• 230/460 or 575 VAC, 3 phase input voltage.
• No control signals are required. Simply connect power supply input and motor output.
• Phase insensitive-L1, L2, L3 input voltage leads can be wired in any sequence.
• UL/cUL Listed

MAC��2000 can be easily applied to an existing contactor on a crane for single- or two-speed applications, or it may be ordered to use with an Electromotive Systems pre-engineered contactor panel.

Pre-Engineered TCONTROLS� Panels 

Electromotive Systems' single motion Pre-Engineered TCONTROLS� Panels feature high-quality, brand name components for precise and reliable performance.

Custom TCONTROLS� Panels 

Electromotive Systems' Custom TCONTROLS� Panels offer the ultimate solution for overhead material handling.

REFLX� COLLISION AVOIDANCE CONTROLS

Electromotive Systems' ReFlx 120 and 120 "Plus" Collision Avoidance Systems enhance the performance of your overhead material handling system by preventing crane to crane or crane to object collisions. And avoiding collisions means reduced maintenance costs and increased operator safety! The ReFlx Systems are ideal for use with all types of adjustable frequency drives and stepped controls.

ReFlx 120 and 120 "Plus" Systems now feature a more reliable, solid-state control board in a smaller enclosure, making it easier to install. This means it can be used as a stand-alone unit, or be removed from its enclosure and mounted as one piece on your existing control sub-panel.

Electromotive Systems offers two types of ReFlx Collision Avoidance Systems.

Reflx 120

 

ReFlx 120 System features a two-channel infrared sensor, which can be adjusted to give separate outputs for each channel at distances from 20 to 120 feet. The most commonly wired configuration is the use of one channel to provide the primary stop command to the motion control, while the second channel is used as a redundant stop command.

The Reflx 120 "Plus"

 

To provide an extra measure of safety to your collision avoidance system, the ReFlx 120 "Plus" offers you the addition of a second, shorter range, sensor. The first sensor, which has two channels, is most commonly wired to use the first channel as a "slow down" command or warning signal, and the second channel as a primary stop command. The second sensor has a single channel, with a range of 1.5 to 20 feet, and is most commonly used as a redundant stop command. The second sensor does not require a reflective target to be utilized.

SYSTEM SPECIFICATIONS

 

ReFlx 120:

• (1) Two-Channel Sensor
• (1) Controller
• (1) Diamond Reflective Target (2ft x 2ft)

ReFlx 120 "Plus":

• (1) Two-Channel Sensor
• (1) Single-Channel Sensor
• (1) Controller
• (1) Diamond Reflective Target (2ft x 2ft)

COMPONENT SPECIFICATIONS

 

Two(2) Channel Sensor:

• Maximum Sensing Distance-120 ft.
• Minimum Sensing Distance -20 ft.
• Enclosure IP65 (NEMA 12, 13)
• Fully Adjustable Scanning Range
• Status LEDs For Each Channel
• 16 ft. Sensor Cable

Single (1) Channel Sensor:

• Maximum Sensing Distance-20 ft.
• Minimum Sensing Distance-1.5 ft.
• Enclosure IP65 (NEMA 12, 13)
• Fully Adjustable Scanning Range
• Status LED For Sensor
• 16 ft. Sensor Cable

Controller:

• Enclosure NEMA 12, 13
• Dimensions-8"H x 6"W x 3.5"D

Black Max� Motors

The Electromotive Systems' Black Max� motor meets the needs of more common crane applications.

Blue Max� Motors

The Electromotive Systems' Blue Max� motor offers the most complete line of inverter duty motors in the industry.

Brake, Encoders & Options

Electromotive Systems offers brakes, encoders and options with our motors line, giving you the highest quality motor with the extra hardware you need to get any job done.

PulseStar��MRT

PulseStar��MRT is a stand-alone remote crane control system. The standard off-the-shelf system is designed for 3-motion, 2-step applications. MRT transmitters are powered with disposable AA batteries, giving you 24 hours of transmitter operating time!

Each value-packed standard MRT system includes:

• Ergonomically designed, lightweight hand held transmitter
• Receiver in IP65 weatherproof enclosure
• Battery holder with 3-"AA" batteries

Available options:

• Custom order transmitters ranging from simple start/stop to single-motion, 2-step configurations
• Rechargeable battery kit

PulseStar��jr

PulseStar��jr. is a low cost, stand-alone, radio remote control system, designed to serve the common three-motion, two-speed overhead crane or monorail hoist.

Each system includes:

• Receiver in IP65 enclosure
• Ergonomic hand held transmitter
• Holster with belt clip
• Two rechargeable batteries
• Battery charger

PulseStar��609

PulseStar��609 remote crane control consists of a standard radio package designed for control of:

• Four, two-step motions using the PBT transmitter
• Three, three-step motions using the NVT transmitter
• Four, five or seven motions, when using selectors on the transmitter.

PulseStar��609 is a pre-engineered, off the shelf system, and is available with more common options.

Each system includes:

• Receiver in IP65 enclosure
• PBT or NVT transmitter
• Carrying belt
• Two rechargeable batteries
• Battery charger

PulseStar��610

Pulsestar��610 systems are designed for use with conventional control systems using reversing contactors or adjustable frequency drives. The engineered building block concept of the 610 system allows for a variety of options by mixing and matching components to develop customized, sophisticated radio configurations. Data feedback, 230 V DC operation, or marine/ hazardous environment applications, are examples of how the 610 system can be easily customized. With the variety of options available with the PulseStar��610, the challenge becomes defining the application so the system can be built to your needs.

The PulseStar��610 system can be furnished with PBT, NVT, or GLT transmitters or a combination thereof.

PBT Transmitter

Weighing under two pounds, the PulseStar� PBT is a single-hand, easy-to-hold push button transmitter. The PulseStar� PBT standard model includes:

• Eight, two-step buttons for four motions, two-speed applications
• Auxiliary button for accommodating latching or momentary, creep speeds, etc.

NVT Transmitter

Our most popular transmitter with the overhead material handling industry, the PulseStar� NVT, is a belly box type transmitter with a sleek, compact and ergonomic design. Standard features on this transmitter include:

• Two, two-axis joysticks to control up to four motions
• Auxiliary toggle
• Three-position selector switch for independent/combined control

This transmitter is also available with three-step detent joysticks for control of up to four motions, and up to six step-less lever masters.

GLT Transmitter

Meeting the demands of special and unique applications, PulseStar� GLT transmitters are built to customer specification. Features include:

• Up to three, dual-axis joysticks or seven lever masters
• Auxiliary toggles
• Three-position selector switch

Also available are a variety of transmitter options, such as:

• Proportional or digital joysticks
• Up to three single-axis levers, one to five-step or proportional
• Lift to operate/push to operate safety switches.
• Lift to operate toggle switches for vacuum/magnet control
• Isolation gates

GLT Transmitter with Data Feedback

Includes the same features and options as the standard GLT plus LCD for remote read out of:

• Weights
• Diagnostics
• Crane position, speeds, etc.
• Order picking and placing
• Many other options

Four-line display with 16 character string per line

Electromotive Systems offers a complete line of festooning hardware and cable to efficiently complete the delivery of power or control in a variety of material handling applications.

Our product range includes:

• Festoon Systems
• C-Track
• Heavy-Duty Aluminum
• Heavy-Duty I-Beam
• Mill Duty I-Beam
• Tag Line Wire Supported

Plug and Play Festoon Hardware

Electromotive� Cable

These versatile systems can be furnished with a myriad of options, offering you maximum flexibility in the design of your festoon system. Components are also available from stock, allowing you to meet the needs of today's most demanding customers.

 

In addition, Electromotive Systems offers a full range of round, flat and specialty cable, designed specifically for festooning applications. Most sizes are available for same day shipment. Round and flat cable can also be ordered with your companies name, logo and phone number in full reel quantities, which reminds customers where you can be reached for new equipment, parts or service.

 

Need your festoon fully assembled to minimize installation time? No problem! Electromotive Systems can furnish pre-assembled and wired festoon systems complete with control box trolleys, pendant stations and plug and play hardware. If you really want to reduce labor expense associated with field wiring order your pre-assembled plug and play festoon system with a matching Electromotive TCONTROL�, IMPULSE�, MAC��2000 or Contactor Panel.

SBP� PENDANT PUSH-BUTTON STATIONS

Featuring a lightweight, ergonomic design, Electromotive Systems SBP� Pendant Push-button Stations provide optimum control and performance with less effort and fatigue than traditional pendants. With most models weighing under two pounds, this slim-line pendant rests easily and comfortably in the palm of your hand. SBP is available in 2 to 12 button configurations, single, two or three speed designs, momentary or maintained on/off, and with a variety of options and accessories.

Standard Features

• Ergonomic design for greater comfort and less fatigue.
• Polycarbonate pendant enclosure is double insulated, chemically resistant and rated NEMA 1, 2, 4, 4x and 12.
• Elastic, chemically resistant gasket ensures a tight seal between enclosure front and back.
• Switches are rated for 3 Amps, 250 Volts AC.
• Single and two-speed button pairs have mechanical interlocks for greater safety.
• Suitable for temperatures ranging from -10�F to 150�F.
• Tapered round cable entry gland can be cut to the proper cable diameter and a slide-on rubber boot ensures a watertight seal.
• Strain relief hardware and plastic cable grip relieves tension on individual cable conductors.
• On 6 through 12 button models, a shrouded knock-out hole is provided for the installation of a pilot light or horn accessory.
• To simplify wiring, a common circuit is pre-wired on all switches.
• A wide variety of specialty and accessory switches are available.
• Standard units ship from stock.
• Factory pre-wired pendants ship with minimal lead time.

We offer standard pre-assembled pendant stations, pendants pre-wired with Electromotive Systems Round Pendant Cable, and custom built pendant assemblies. The choice is yours.

SBP2� PENDANT PUSH-BUTTON STATIONS

Featuring a lightweight, ergonomic design, Electromotive Systems SBP2 Pendant Pushbutton Stations provide optimum control and performance with less effort and fatigue than traditional pendants. With most models weighing under two pounds, this slim-line pendant rests easily and comfortably in the palm of your hand. Quick delivery a priority? Not a problem - most standard SBP2 pendants are available from stock and can be shipped the same day we receive your order. And, with a high-impact resistant, watertight enclosure to survive the most brutal environments, SBP2 is ideally suited for any industrial application.

SBP2 has been extensively tested to insure quality and years of reliable service.

The photo (at right) shows the SBP2 pendant switches during a one million cycle test.

Standard Features

All SBP2 pendant pushbutton stations include the following features:

• Ergonomic design for increased comfort and decreased fatigue
• Impact resistant pendant enclosure is double insulated, chemically resistant and rated NEMA 1, 3, 4, 4X and 12
• Mechanical interlocks on Single- and Two-Speed switches for enhanced safety
• Cumulative contacts on Two- and Three-Speed Switches provide precise detent feel
• Switches are rated 3 Amp, 250 Volt AC
• Easy-to-read button functions
• Dual stainless steel hanger rings allow for easy attachment to strain relief cable
• Easily removable button hoods and nameplates
• Operating temperature range: -10� F to 150� F
• UL/CUL approved
• Quick delivery of standard models from stock

Options:  Pendant Station

Configured with the various accessories listed below, SBP2 may be customized to meet any application requirement.

• Single Speed Switch inserts with one normally closed (N.C.) and one normally open (N.O.) contact per button
• Mechanical interlocks on Single- and Two-Speed switches for enhanced safety
• 120 Volt AC pilot light (mounting in upper left hand accessory hole and/or standard button hole)
• On/Off key switch with key removable in off position
• Two and three position selector switches
• Four position selector key switch with key removable in the fourth (off) position
• Red mushroom On/Off switch
• Blank to cover button hole
• J-Box mounting for additional switches and/or indicating lights
• Tandem Mounting (8-12 Button Pendants) for multifunction/automation applications
• Stainless steel wire mesh cable grip

Custom single and double T-box configurations are available. Consult factory for additional information.

ELECTROBAR�, ELECTROBAR FS�, ELECTROBAR ELITE� AND FABA� ENCLOSED CONDUCTOR BAR SYSTEMS

Providing an array of options and accessories, Electromotive Systems offers the following conductor bar systems:

8-Bar

 

An enclosed conductor bar system used interchangeably with common bottom entry 8-Bar designs. Available for 90, 110, 250 and 350 Amp systems.

V-Bar

 

An enclosed conductor bar system with an inverted V running surface for positive tracking of the collector shoe. Available are 90 and 110 Amp systems.

HX Series

 

An aluminum extruded inverted high amperage conductor bar with stainless-steel lined contact surface. Available in 400, 700, 1000 and 1500 amp designs for 600 volts A.C./250 volts D.C. heavy duty applications. The conductors are joined with a bolted joint kit connection assembly that assures the full current carrying capacity without interfering with the free travel of the collector contact and is designed to automatically allign the conductor bar sections during installation. Nylon span-in, steel clamp or insulated hanger assemblies provide an additional level of insulation as well as rigid support of the conductor sections. Collector assemblies are offered in single or double copper graphite contact shoe arrangements that accomodate travel speeds of up to 900 ft per minute.

Collector Assemblies UL Listed

for 8-Bar, V-Bar, FS-Bar, and HX Series Collector Systems

 

Electromotive Systems provides collector assemblies featuring corrosion resistant, pivot pins and impact-resistant poly-carbonate arms and body which are universally interchangeable. The impact-resistant polycarbonate arms are electrically insulated, and are safety-yellow in color for improved visibility. (These units are available in single and double shoe configurations for 8-bar and V-bar from 100 to 200 Amps. The same collector assembly is used for our HX series bar with a different head assembly rated from 200 to 400 Amps.)

ELECTROBAR� FS 

We're proud to introduce our new Electrobar FS� Conductor Bar System for the electrification of cranes, monorails and automated storage and retrieval systems! Here are just a few of the important features the Electrobar FS Conductor Bar system has to offer:

• A unique shape that maximizes safety and performance
• A UL Listed "finger safe" design that minimizes the potential for electrical contact
• Easy installation and maintenance, which reduces labor costs.

Available in 90, 110, 125*, 250 and 400 AMP ratings, and single and double shoe collector assemblies. Snap-in hanger kits are available for 2, 3 and 4 pole applications.

 

*Suitable for 125 Amp configurations in non-UL applications.

ELECTROBAR ELITE� 

 

Electrobar Elite�  A totally enclosed 4 conductor bar system available in 60, 100, 130 and 200 Amp configurations. IP23 Finger Safe Rating. Lightweight, rigid design. Modular construction and other design features significantly reduce installation time and cost as compared to other conventional conductor bar systems.

FABA�

FABA� A small, compact multi-conductor bar system designed for automated electrified monorail (AEM) systems, up to 100 Amps.