Insul-8 Mobile ElectrificationCable Reels ◆ Conductor Bar ◆◆ Festoon ◆ Pendants ◆◆ Radios ◆ Slip Rings
Solutions From A Single Source
Motor DrivenCable Reels
For the Electrification of:
●● Port Cranes
●● Iron and Steel Mill Equipment
●● Bulk Material Handling Equipment
●● Yard Equipment
●● Mining Equipment
MOTOR DRIVEN REELS
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INSUL-8 – CONDUCTIC DIVISION
INSUL-8 – CONDUCTIC DIVISION
Insul-8 Corporation designs and manufactures equipment that provideselectrical power to mobile and stationary equipment from small toolsand automated machinery to large container cranes and transit systems.Our full line of power delivery equipment includes: Spring and MotorDriven Cable Reels, Conductor Bar from 40 to 6000 amperes, C-Trackand I-Beam Festoon, and Slip Rings. Insul-8 can design and manufacturea system that is right for your demanding application.
CONDUCTOR BAR SYSTEMSFull range of insulated conductorbar designs from 40to 6000 amperes.Many special designssuch as collectors,insulated covers, and conductor barscan be modified to fit your application.Conductor bar is used in standardapplications such as overhead cranebridge and runway electrification anddockside cranes, to large, complextransit systems.
MOTOR DRIVENREELSWide range of stan-dard and customdesigns to meetyour specifications.IER™ Motor DrivenCable Reels primarily
use the magnetic coupler drive pack-age for reliability and long-life dependability. Motor Driven Reelsare used in a wide variety of applica-tions including material handling,portside cranes, yard cranes, andmill applications.
FESTOON SYSTEMSStandard and customdesigns to satisfy anyapplication. Festoonline includes stretchedwire for small, light-duty applications, C-Track for standard industrial applica-tions, square bar for highly corrosiveenvironments, and I-Beam systemsfor up to 600 lbs. per carrier.Festoon is used for management ofpower and control cables for mobileequipment such as overhead andportside cranes.
SLIP RINGSInsul-8 designs andmanufactures themost rugged depend-able IER™ slip ringsand enclosures foruse of supplying 360ºcontinuous power.
Whether you need a simple1.5" bore, aself-contained assembly, or a complexenclosed ring, Insul-8 can provide thesolution.
SPRING DRIVENREELS Wide range of stan-dard and customdesigns to meet yourapplication. Springreels are used inapplications such as
workstations, automated machinery,boom trucks, extendable conveyors,and hundreds of specially engineeredapplications.
MOTOR DRIVEN REELS
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MOTOR DRIVEN REEL COMPONENTS
BASIC COMPONENTS OF A IER™ MOTOR DRIVEN REEL
65
4
3
2
1
MAIN GEARBOX UNIT• 7 sizes
ADDITIONAL GEARBOXES• 5 different models
SECONDARY GEARBOXES• 9 different models
DRIVE UNIT:• Common electric motor and the
magnetic coupler• 3 models
SPOOL• 5 types and an extended range of
sizes and options
SLIP RING ASSEMBLY• Power, control, mixed power/control,
fiber optic transmitter
1 4
5
6
2
3
MOTOR DRIVEN REELS
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DRIVE OPTIONS
IER™ MAGNETIC COUPLER DRIVE
IER™ TORQUE MOTOR DRIVE
IER™ ELECTRO-HYDRAULIC DRIVE
• Because of its simple operating principles, the magnetic coupler drive is among the most economical of all drive systems.
• Smooth consistent torque assures maximum cable life.
• Compact design requires minimal space.
• Continuous 100% stall duty rating.
• No loss of cable tension during power outage.
• Critical components are completely sealed and protectedfrom the atmosphere.
• Explosion-proof reels available.
• The drive consists of a totally enclosed electric motor driving a hydraulic pump mounted on a hydraulic reservoirthat includes the fittings, gauges, control valves, and interconnected plumbing necessary for automatic operationof the reel.
• Simple torque and speed adjustment.
• Drive is well-suited for high speed and high torque applications.
• Hydraulic pump can be driven by single or three-phase A.C. and D.C. standard electric motors.
• Explosion-proof reels available.
• Torque Motor, 100% stall, 3-phase torque motors.
• Rugged design, minimal maintenance required.
• Frame is considerably larger than standard motor frame size because of the need to dissipate heat.
• Explosion-proof reels available.
MOTOR DRIVEN REELS
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SPOOL OPTIONS
TYPICAL SPOOLS
IER™ Motor Driven Cable Reels come in a variety of spool configurations including bulk wrap, monospiral, and level wind. A comparison chart of the various spool configurations is given below.
Bulk Wrap:Four wraps max. (standard),
67% fill (average).
Monospiral:One wrap wide designed to
accommodate two dead wraps& one safety wrap at the rim.
Level Wind:One layer standard with two tofour layers available. Designed
to accommodate two deadwraps & four wraps.
SPOOL OPTIONS
Type of Reel Bulk Wrap Monospiral Level Wind
Reel Size
Spool Diameter
Drum-to-Spool Rim Ratio
Line Pull Variance
Output Torque
Wrapping Characteristics
Applying Cable Guides
Cable Selection(Based on derating)
Cost Index Less Cable
Overall Cable Life
Shipping & Installation
Smallest
Small
2.5 Average
Variable
Average
Not controlled
Difficult
Max. deratingrequired
Low
Low
Normal
Medium
Large
2.5 Average
Variable
Greatest
100% positive
Not difficult
Min. deratingrequired
Medium
Medium
Normal
Medium
Medium
None
Constant
Medium
Good but must be controlled
Not difficult
Min. deratingrequired
High
High
Normal
MOTOR DRIVEN REELS
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SLIP RINGS
IER™ STANDARD SLIP RINGS
IER™ HIGH VOLTAGE SLIP RINGS
Heavy industrial-duty slip ring assembliesare supplied on all IER™ Motor DrivenReels.
The slip rings are copper alloy with finelymachined surface finish to afford concentricityand minimum brush-to-ring contact resistance.The brushes are copper graphite, precision-machined to contact the diameter of the sliprings at 100% rated current collection.
The rugged, corrosion-resistant metal brushholders have a hinged mounting clamp forprecision adjustment and can be individuallyremoved from the slip ring assembly. Theholder’s adjustable brush springs are factoryset for the proper amount of tension, thuseliminating the possibility of the spring
becoming loose, resulting in the loss of brush spring tension.
The slip ring insulators are composed of high di-electric strength, shock and moisture-proof, glass-filledmaterial providing an extremely high arc resistance and comply with IUL self extinguishing (SE-1) require-ments. The insulator barriers (widths complying with UL standards for general purpose reels) are rated for600 volts on reels using up to 4 conductors. Reels with over 4 conductors are rated for 250 volts per ULrequirements. The insulator barriers (widths complying with UL standards for special use reels) are ratedfor or at 600 volts for any number of conductors.
These slip rings are constructed with all the samefeatures which are found on the 600 volt rings. Inaddition, surface and air gaps have been expandedin accordance with NEC specifications for highvoltage apparatus. High di-electric strength insulatorspacers are installed between conductors toincrease surface gap. The 5-8Kv rings are eachtested with a DC Highpot at 22Kv. The maximumallowable current leakage is 150 microamps withan average current leakage of less than 55microamps. High-voltage rings are available in allcurrent ratings shown for 600 volt rings. The 10-25Kv slip rings incorporate an air gap construc-tion. A ground check ring (usually 35 ampere, 600 volt) is furnished on most high-voltage rings.
MOTOR DRIVEN REELS
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DRIVE CONFIGURATIONS
IER™ MAGNETIC COUPLER DRIVE CONFIGURATIONS
7
6
5
4 3
2
1
1
5
3
4
2
2
3 4
1
1
3
2
2 1
1
“V” Coupler
“W” Coupler
“C” Coupler
Secondary gear boxes
BNA7
BNA5
BNA4
BNA3
BNA2
BNA1
MOTOR DRIVEN REELS
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MAGNETIC COUPLER DRIVE
OPERATING PRINCIPLES OF THE IER™ MAGNETIC COUPLER DRIVE
IER™ Magnetic Coupler can be driven by any substantial constant speed power input (normally a1725 RPM electric motor).
The power input turns the driving magnet (#2) at motorspeed. An air gap (#3) separates the driving magnet(#2) from the driven magnets (#4), spool side. Thespeed differential (slip RPM) between the electric motorshaft (driving magnet) and the cable reel spool (drivenmagnets) is accommodated by the hysteresis couplerusing an air gap with the resulting magnetic coupler asthe slipping interface. The magnets within the couplerare all permanent; therefore, the clutch requires noexternal power or controls.
The rating of the coupler is continuous and can be 100% stalled, with heat dissipated by the rotating magnet enclosure (#6). The output torque can bechanged by adjustment of the air gap (#5). The one-way bearing (#1) on the input side allows the magnets to become a brake if the motor is shut off.
Backstop Bearing
Driving Magnets
Air Gap
Driven Magnets
Air Gap Adjustment
Rotating Magnet Enclosure
Output Bearings
Protective Cage Enclosure
1 2 3 4 5 6 78
12345
6
7
8
INDUCED PART INDUCER
AIR GAP
MOTOR DRIVEN PART
MOTOR DRIVEN REELS
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MAGNETIC COUPLER DRIVE
ADVANTAGES OF THE IER™ MAGNETIC COUPLER DRIVE
• Permanent Magnets - No electric coils or D.C. power supply are required.• Explosion Proof - Because there is no mechanical connection between the permanent magnets
Insul-8 can accommodate most explosion-proof reel requirements.• Minimal Maintenance - The sealed ball bearing requires little or no maintenance. The gearbox and
gear reducers all have gears running in oil. You can expect a 5-year life or 15,000 operating hours without any standard maintenance.
• Fully Adjustable - All magnetic (hysteresis) couplers can be adjusted by changing the air gap betweenpermanent magnets. Lower torque settings are preferred because less stress is applied on the cable.
• 100% Stall Duty - Motor turns at nameplate speed (usually 1725 RPM) while spool is turning at zero speed at 100% stall.
• Standard Motors - Any NEMA C-faced motor of the proper size can be mounted to the hysteresiscoupler. Generally the electric motors used are a stock “off the shelf” item and are readily available.
• Braking - The “one-way” bearing will only rotate in one direction. This eliminates any free-wheelingof the spool, and acts as a brake.
• Power Consumption - Permanent magnet couplers use less power than other electric motor-drivenreels. When compared with 100% stalled electric torque motors, only half of the electric power isrequired.
Cut-A-Way view of a typical Magnetic Coupler Drive
With our modular design concept, which involves building reeling devices using several variations of 83 gear reducer drives along with our 30 basic spool designs and all of our stan-dard collector ring designs; IER has the experience and expertise to build a reel to meetyour application requirements.
MOTOR DRIVEN REELS
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CABLE GUIDES
IER™ CABLE GUIDES
Many cable reel applications require the use of cable guides to serve the cable in various directions. An improperlydesigned or misapplied cable guide can become a source for immediate problems affecting not only the operatingperformance of the reel, but also causing considerable damage to the cable. With this in mind, the cable guidesoffered are based on design criteria obtained through many years of experience and explained by the dissertationin the various guides below. All of the cable guides offered afford the user minimum bend diameter recommendedby most cable manufacturers.A) Single and multiple conductor cables, 600 volt rated, up to 6 conductors max.-12 x diameter of cable.B) Multiple conductor cables, 600 volt rated, 7 or more conductors-16 x diameter of cable.C) Multiple conductor cables, 5Kv rated, power cables-12 x diameter of cable.D) Multiple conductor cables, 8Kv through 25Kv rated, power cables-16 x diameter of cable.
Standard Two-way Payout (Fig. 1): The type G/M multiple rollercable guide is used where cables are served in two directions andone end of the cable is terminated at the center of the total machinetravel. Attachment of the cable at the center feed must be in the samevertical plane as the cable guide to provide straight line pickup. Themultiple roller two-way guide is used where structural members orother obstructions would interfere with the normal windup and payoutattitudes of the cable. The multiple roller two-way cable guide isequipped with flat faced rollers to provide minimum contact with thecable.
For certain classes of service, smaller guide rollers can be more economically used, but it is never advisable to use cable guides withsmaller bend diameters than the cable manufacturers recommended minimum. All multiple roller cable guides require separate mountingfrom the reel.
Standard Two-way Payout with Slack Cable Detection (Fig. 2):The type G/M-S multiple roller cable guide detects a slack cable condi-tion by use of a guide pendulum swinging in an arc controlled bycable tension. By use of a rotary geared limit switch on the cablereel and snap type limit switches on the cable guide, a condition ofslack cable is automatically detected. The wiring of these switches inconjunction with the machine travel permissive relay circuit will auto-matically stop the machine in the event of slack cable. The slackcable initiating contacts are inhibited at the zero deflection point(passing over the center feed point) allowing the machine to travelthrough this point without shutting down.
Standard Two-way Payout with Overtension and Slack CableDetection (Fig. 3): The type G/M-S-O multiple roller cable guide functions in the same manner as the type G/M-S and has the addedfeature of detecting cable overtension. Cable controlled swingingarms will initiate contacts of limit switches, controlling both directionand overtension conditions.
Two-way Payout Anchor (Fig. 4): As the name implies, it serves as an anchoring device for the free end of the cable in two-way payoutapplications. It is usually installed below the level of the grade to allowthe cable to transfer over the center point without damage to the cable.
(Fig. 4)
CABLE GUIDE DESCRIPTIONS
(Fig.1)
(Fig. 3)
(Fig. 2)
MOTOR DRIVEN REELS
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MOTOR DRIVEN REEL OPTIONS
CONSTANT PULL REGULATION
PULL & STORE
FIBER OPTIC TRANSMITTER
COMESFLEX
A) Constant Pull (Open Loop): It is referred to as an “open loop” as all information required to control the reel drive is relayed by the crane control system.
B) Constant Pull (Closed Loop): This system is referred to as a “closed loop” as all the information required to regulate the reel drive is gathered by a sensor on the reel itself.
Insul-8 has added the Pull & Store reeling system for cable management. This system has been addeddue to the increased speed requirements, and the need to reduce line pull on the cable itself, as well asaddition of fiber optics in many applications.
The system uses two reels. A small pull reel is used to “pull” the cable up slightly higher than the storagereel in diameter to provide at least 120 degrees of contact area over the circumference of the spool drum.The drive unit of the pull reel creates sufficient pull to lift the cable off the ground to the height that the tworeels in the system are mounted.
The Delachaux Group was the first cable reel manufacturer to develop a continuous fiber optic transmitter. It allows the transmission of large amounts of information with low-level attenuation - less than 1 dB without strain on the fiber optics.Automated stacking cranes and continuous container unloadersrely on the transmitter to keep up with the greater stream of computer data, video signals of high-speed, efficient operations.
The trench cover protects against damage to powerand control cable caused by vehicles or falling objects.This simple but effective system includes trench channel protective material and a steel plate. COMES-FLEX is a recommended accessory where there is highrate of traffic around the primary moving application.
MOTOR DRIVEN REELS
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IER™ MOTOR DRIVEN REEL APPLICATIONS
PORT EQUIPMENT
• Ship to Shore Container Cranes
• Rail Mounted Gantry Cranes
• Mobile Harbor Cranes
• Whirley Cranes
Container CraneTo retrieve 1100 feet of #2 AWG, 3 conductor,type SHD-GC-5 KV high voltage cable.
Ship LoaderTo retrieve 800 feet of #1/0 AWG, 3 conductor,SHD-GC-8 KV high voltage cable.
MOTOR DRIVEN REELS
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IER™ MOTOR DRIVEN REEL APPLICATIONS
MILL EQUIPMENT
• Tundish Cars
• Magnet Cranes
• Transfer Cars
• Ladel Cars
BOF area, ladle stirring application. To retrieve, 90 feet of 1" I.D. hose carrying argon gas.
Magnet CraneTo lift 85 feet of #2 AWG, 2 conductor, magnet cable.
MOTOR DRIVEN REELS
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IER™ MOTOR DRIVEN REEL APPLICATIONS
BULK MATERIAL HANDLING EQUIPMENT
• Stacker Reclaimers
• Mobile Trippers
• Ship Loaders & Unloaders
• Clamshell Unloaders
• Shuttle Conveyors
Stacker ReclaimerTo retrieve 550 feet of #4 AWG,3 conductor, 5 KV, plus 6 fiberoptic fibers combination cable.
MOTOR DRIVEN REELS
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IER™ MOTOR DRIVEN REEL APPLICATIONS
YARD EQUIPMENT
OTHER EQUIPMENT
• Yard Cranes • Portal Cranes
• Gantry Cranes
• Refuse Cranes
• Pallet Loaders
• Tunnel Boring Machines
Tripper ConveyorTo retrieve 600 feet of #4 AWG, 3 conductor,type G-GC, 600 volt cable.
Log Handling CraneTo lift 60 feet of 12 AWG, 12 conductor,type SO cable for grapple.
Container Spreader To lift 130 feet of #12 AWG, 36 conductor, type SO cable.
Phosphate LoaderTo lift 125 feet of #12 AWG, 20 conductor, type SO cable.
MOTOR DRIVEN REELS
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IER™ MOTOR DRIVEN REELS
MOTOR DRIVEN REELS
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QUOTATION INFORMATION
MOTOR DRIVEN REEL CUSTOMER CHECKLIST
Date:___________________________________ Salesperson: _____________________
Required by: _____________________________________________________________
Customer: _______________________________ Job #: __________________________
Qty: ____________________________________ Cat #: __________________________
Phone: __________________________________ Fax: ___________________________
AWG _______ No. of conductors ________ Type _________ Stranding ______________
Voltage _______________ Diameter ______________ Weight (lb./ft.)________________
If composite cable, describe _________________________________________________
Maximum cable payout length _____________________________ total travel distance or
active cable length of machine _______________________________________________
(If cable feed point is at the center of total travel distance, maximum cable payout length isequal to 1/2 of the total travel distance of machine)
Note: Total length of cable will include payout length + reel height above cable support surface + 2 dead wraps + length for connections.
Retrieve ___________________________________________________________
Lift _______________ Active length _______________Total length____________
Stretch ____________ % Sag ____________________
Drag_________________________________________
If retrieve, what is the approximate height the reel base will be mounted above the cablesupport surface ____________ ft.?
I.D.__________ O.D._________ P.S.I._________ Air/Water_________
Gas__________ Hydraulic_________ Other_________
Machine Total H.P._______ @ __________ volts.
Required amperes ________________________________________________________
CABLE SPECIFICATIONS
HOSE SPECIFICATIONS
MOTOR DRIVEN REELS
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QUOTATION INFORMATION, CONT.
MOTOR DRIVEN REEL CUSTOMER CHECKLIST, CONT.
Total H.P. working simultaneously_____________________________________________Required amperes ________________________________________________________Duty cycle of machine _____________________________________________________Travel speed of machine (ft./min.)_____________________________________________Acceleration______________________________ ft./sec.2 or time_______________ sec.Does machine coast when power is off? _______________________________________Environmental conditions __________________________________________________________________________________________________________________________
Operating position of reel ___________________________________________________
Cable guides required? ___________________________ Type_____________________
Type: Stall torque motor__________________ Electro hydraulic ___________________Mag coupler______________ Air motor________________ Constant Pull Regulation (open or Closed Loop) ______________
Motor voltage__________________ Phase________________ Cycles_______________
Motor enclosure: Totally enclosed __________________________________________orClass ________________ Div._______________ GRP_____________Other ____________________________________________________
Type of System: Bulk Wrap ______________________Monospiral__________________Level Wind____________________ Pull & Store___________________
Is an enclosure anti-condensation heater & thermostat desired? ____________________Voltage _________________________________________________________________
Is an external junction box with terminal strips pre-wired to collector ring desired?______________________________________________________________________________
Paint: Mfg Std. ________________Special Prep_____________ Special_____________
Cable last wrap limit switch desired? __________________________________________Special construction specifications (describe or furnish) __________________________________________________________________________________________________
Remarks _______________________________________________________________________________________________________________________________________
THE DELACHAUX GROUP
DELACHAUX: MULTI LOCAL SERVICE, WORLDWIDE
PARTNERS/SUBSIDIARIESFRANCEDELACHAUXJ.P. HUGUETJ.P. LELONG119, av. Louis Roche92230 GENNEVILLIERSTél. (16) 1 46 88 15 00Fax (16) 1 46 88 15 21(Siége Social et Usine)
DELACHAUXJ.P. NEHRJ.F. LE GOULVEN30, av. Brillat-Savarin01300 BELLEYTél. 79 42 50 70Fax 79 42 50 75(Usine)
DELACHAUXGérard GELLELa ChasseLe Bignon44140 MONTBERTTél. 40 04 78 38Fax 40 26 72 53
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AUSTRALIAINSUL-8 LtdCONDUCTIC DIVISIONGraham GOODMAN14 England StreetDandenong-VictoriaTel. (61) 3 97 06 88 44Fax (61) 3 97 94 92 98
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CANADAINSUL-8 CORPORATION LtdCONDUCTIC DIVISIONJacques PRECOURT175, boulevard J.F. KennedySaint JérômeQUEBEC J7Z 4B5CANADATel. (514) 565 91 00Fax (514) 432 69 85Telex 5839 543
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MEXICORAILTECH CALOMEXS. DE R. L. DE C. V.Bruno LEPINEMarconi n° 6Fracc. IndustrialSan Nicolas54030 TlalnepantlaMEXICOTel. (5) 253 10 93 71
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NORWAYASIASI CONTROL TECHNIQUES ASMotor Drive CentreBjorn NILSENIngvald Ludvigsensgate 23P.O. Box 70443007 DRAMMENTel. (47) 32 23 51 00Fax (47) 32 23 51 01
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U.S.A.INSUL-8 CORPORATIONCONDUCTIC DIVISIONLon MILLER10102 F StreetOmaha, NE 68127USATel. (402) 339-9300Fax (402) 339-9627
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Electrification Solutions from a Single Source
CANADA175 Boulevard J.F. Kennedy
St. Jerome, Quebec J7Y 4B5
Phone: (450) 565-9900Toll Free: (800) 667-2487
Fax: (450) 432-6985e-mail: [email protected]
USA10102 F Street
Omaha, NE 68127
Phone: (402) 339-9300Toll Free: (800) 521-4888
Fax: (402) 339-9627e-mail: [email protected]
AUSTRALIA:14 England StreetDandenong, Victoria 3175
Phone: (3) 9706 88 44Fax: (3) 794 92 98
e-mail: [email protected]
Distributed By:
SPRING DRIVENREELS
SLIP RINGS FESTOON
CONDUCTOR BAR
CONDUCTOR BAR
Push Button Pendants
Please visit our websites at:www.insul-8.com
ISO 9001 Certified
2010 06/96JMK/OP
