romotive Electromotive Systems Electromotive SystemsSystems

se™ DDC OmniPulse Digital DC™Drive DDC OmniPulse Digital™ DC DDCDrive Digital DC Drive

INCREASE INCREASE YOURYOUR COMPETITIVE COMPETITIVE INCREASE ADVANTAGE YOUR ADVANTAGE COMPETITIVE ADVANTAGE

CONVERT CONVERT YOUR YOUR DC CONTROLS DC CONTROLS CONVERT TO STATE-OF-THE-ART TO YOUR STATE-OF-THE-ART DC CONTROLS ENERGY ENERGY TOEFFICIENT STATE-OF-THE-ART EFFICIENT ENER OMNIPULSE OMNIPULSE DDC DIGITAL DDC DIGITAL DC OMNIPULSE DRIVES DC DRIVES DDC DIGITAL DC DRIVES Magnetek, Magnetek, the leaderthe in leader crane and in crane hoist and motor Magnetek, hoist control, motor the control, leader in crane and hoist motor control, brings you brings the OmniPulse you the OmniPulse DDC Digital DDC DCDigital brings Drive.DC you TheDrive. the Energy OmniPulse The Energy DDC Digital DC Drive. The Energy ™ ™ ™ Engineered Engineered OmniPulse OmniPulse will improve will the improve performance Engineered the performance OmniPulse will improve the performance and reliability and reliability of your DC of operated your DC operated crane and or hoist, crane reliability while or hoist, of your while DC operated crane or hoist, while minimizing minimizing downtime,downtime, maintenance maintenance expenses minimizing expenses and energy downtime, and energy maintenance expenses and energy costs. It’s costs. the smart It’s the choice smart in choice crane control in crane costs. that control will It’s pay the thatsmart will pay choice in crane control that will pay dividendsdividends and provide andyour provide facility your with facility a dividends competitive with a competitive and provide your facility with a competitive advantage advantage for years for to come. years to come. advantage for years to come. EFFICIENTEFFICIENT OPERATION OPERATION EFFICIENT OPERATION OmniPulse OmniPulse DDC employs DDC semiconductor employs semiconductor technology, OmniPulse technology, which DDC employs whichsemiconductor technology, which provides better provides control better ofcontrol motor speed of motor and speed provides torque and than better torque costly, control than costly, of motor speed and torque than costly, inefficientinefficient DCCP control. DCCPThis control. microprocessor This microprocessor inefficient based,DCCP solidbased, control. solid-This microprocessor based, solidstate, four-quadrant state, four-quadrant DC-to-DC DC-to-DC control is control designed state,isfour-quadrant designed for series,for DC-to-DC series, control is designed for series, shunt, or compound shunt, or compound wound motors. wound motors. shunt, or compound wound motors. IDEAL DROP-IN IDEAL DROP-IN REPLACEMENT REPLACEMENT IDEAL DROP-IN REPLACEMENT OmniPulse OmniPulse DDC is the DDC perfect is thedrop-in perfectreplacement drop-in OmniPulse replacement forDDC isfor the perfect drop-in replacement for traditionaltraditional electromechanical electromechanical controls. Itcontrols. eliminates traditional It eliminates routine electromechanical routine controls. It eliminates routine and costlyand contactor costly contactor tip replacement tip replacement and reduces and and costly energy reduces contactor energy tip replacement and reduces energy expenses.expenses. It easily interfaces It easily interfaces to existingtopower existing expenses. and power It easily and interfaces to existing power and control circuitry controlusing circuitry the using same the connection same connection control points circuitry in a pointsusing in a the same connection points in a smaller footprint. smaller footprint. smaller footprint. IMPROVED IMPROVED CONTROL CONTROL AND SAFETY AND SAFETY IMPROVED CONTROL AND SAFETY Most importantly, Most importantly, Omnipulse Omnipulse DDC will DDC also Most improve willimportantly, also safety improve Omnipulse safety DDC will also improve safety in your facility. in yourThe facility. OmniPulse The OmniPulse DDC provides DDC in your failsafe provides facility. torque failsafe The OmniPulse torque DDC provides failsafe torque proving and proving load and control load software, control software, ensuring proving the ensuring operator andthe load operator control software, ensuring the operator always has always control has ofcontrol the material. of the material. always has control of the material. MINIMIZED MINIMIZED DOWNTIME DOWNTIME AND IMPROVED ANDMINIMIZED IMPROVED SERVICEABILITY DOWNTIME SERVICEABILITY AND IMPROVED SERVICEABILITY We knowWe production know production needs change. needs That’s change. We why know That’s OmniPulse production why OmniPulse needs change. That’s why OmniPulse DDC wasDDC designed was designed with comprehensive with comprehensive software DDC was that software designed provides thatwith provides comprehensive software that provides superior flexibility superior flexibility and allows and forallows quick for parameter superior quick parameter changes. flexibility changes. and allows for quick parameter changes. (Software(Software upgradesupgrades can be flashed can befrom flashed a(Software PC). from These a upgrades PC). Thesecan be flashed from a PC). These parameters parameters allow the allow drive the to compensate drive to compensate parameters for the mechanical forallow the mechanical the drive to compensate for the mechanical timing of timing the crane, of the increasing crane, increasing brake lifebrake and timing plant life ofand the efficiency. crane, plant efficiency. increasing brake life and plant efficiency. 4HE/MNI0ULSE$$#ALSOINTERFACESWITH)-05,3%s,INK 4HE/MNI0ULSE$$#ALSOINTERFACESWITH)-05,3%s,INK 4HE/MNI0ULSE$$#ALSOINTERFACESWITH)-05,3%s,INK Basic or WDS Basic (wired or WDS or (wired wireless), or wireless), offeringBasic remote offering or parameter WDS remote (wired parameter or wireless), offering remote parameter modification modification and diagnostic and diagnostic capability.capability. modification and diagnostic capability.

HE OMNIPULSE THE OMNIPULSE DDC DDC DRIVE THE OMNIPULSE DRIVE OUTPERFORMS OUTPERFORMS DDC TRADITIONAL DRIVE TRADITIONAL OUTPERFORMS TRADITIONA OMN CCP CRANE CRANE CONTROLS CONTROLS DCCP CRANE CONTROLS GENE NT DCCP

OMNIPULSE OMNIPULSE DDC DIGITAL DDCCRANE DIGITALCONTROL CRANE OMNIPULSE CONTROL DCCP ELECTROMECHANICAL DDCDCCP DIGITAL ELECTROMECHANICAL CRANE CONTROL CRANE CONTROLS CRANE DCCP CONTROLS ELECTROMECHA BETTER MOTOR BETTER SPEED MOTOR AND TORQUE SPEED AND CONTROL TORQUE CONTROL BETTER MOTOR SPEED AND TORQUE CONTROL

eed Transitions Speed Transitions

Digital microprocessor Digitalcontrol microprocessor with flexible control software with flexible enablessoftware smooth enables acceleration Digital smooth microprocessor acceleration Contactor, control relaywith Contactor, andflexible resistorrelay software based andcontrol resistor enablesmeans based smoothmore control acceleration rigid means transitions moreContactor, rigid transitions relay and resistor based c Horsepower Speed Transitions and deceleration,and reducing deceleration, current reducing spikes and current excessspikes mechanical and excess torque mechanical and deceleration, torquebetween reducing speed current between points spikes andspeed and no reduction excess points mechanical and of no mechanical reduction torquetorque of mechanical between torque speed points and no reduc

ad Positioning Load Positioning

Continuous Use of resistors Use for speed of resistors points,forwhich speedarepoints, subjectwhich to alterations are subjectover to alterations Use timeof resistors over time for speed points, wh Repeatable and Repeatable accurate and settings accurate mean speedprecise settingsload mean positioning precise load Repeatable positioning and accurate speed settings mean precise load positioning Loadspeed Positioning due to heat, results due to in inconsistent heat, resultsload in inconsistent positioningload positioning due to heat, results in inconsistent l

Reduces cycle time Reduces by increasing cycle timeno-load by increasing speeds inno-load both upspeeds and down in bothmotions. Reduces up and down cycle motions. time by increasing no-load speeds in both up and down motions. Input Voltag No load/high speed No load/high lowering speed is not possible lowering with is notDCCP possible control with DCCPNocontrol load/high speed lowering is not ht Load High LightHook Load Speeds High Hook Speeds Light Load High Hook Speeds Micro Speed feature Microoffers Speedstillfeature finer load offerspositioning still finer load accuracy positioning accuracy Micro Speed feature offers still finer load positioning accuracy

ntrolled Plugging Controlled Plugging

Digital technology Digital provides technology controlled, provides repeatable, controlled, accurate repeatable, and variable accurate Digitaland technology variable provides controlled, repeatable, accurate and variable Plugging torquePlugging inconsistent torque inconsistent Controlled Plugging plugging to stopplugging or reverse to stop or reverse plugging to stop or reverse

eed Regulations Speed Regulations

Software provides Software 5% speed provides regulation, 5% speed no load regulation, to full load no load to fullSoftware load provides Due to5%load speed changes regulation, Due toand loadthe nochanges effect load tothat and fullheat the loadeffect has onthat theheat repeatability has on the Due of repeatability to load changes of and the effect Speed Regulations Motor Circui (0.1% with tachometer (0.1% with feedback) tachometer feedback) (0.1% with tachometer resistors, speed feedback) resistors, regulationspeed variesregulation greatly varies greatly resistors, speed regulation varies gre

Plugging torque inconsistent Current Ove

MINIMIZED DOWNTIME MINIMIZED AND DOWNTIME IMPROVED ANDSERVICEABILITY IMPROVED SERVICEABILITY MINIMIZED DOWNTIME AND IMPROVED SERVICEABILITY Control softwareControl is capable software of supporting is capablevarious of supporting materialvarious handlingmaterial Control handling software is capable of supporting various material handling

applications. monitorRemote and parameter monitor modifications and parametercanmodifications be made applications. viacan be made Remote Not possible—need via monitor Not andpossible—need parameter to change modifications hardware to changecanhardware be made via ogramming Programming Flexibility Flexibility applications. Remote Programming Flexibility )-05,3%s,INK )-05,3%s,INK

)-05,3%s,INK

Discrete Con

Not possible—need to change hard

Analog Inpu

Solid-state design Solid-state consists of design fewerconsists electromechanical of fewer electromechanical components thatcomponents Solid-state wear design that Many wear consists moveable of Many fewer components moveable electromechanical wear components and fail components over weartime andthat needing failwear overintensive time needing Many moveable intensive components wear a Number of Components Programma and fail. and fail. maintenance (Amaintenance DDC drive can(Areplace DDC drive up tocan9 replace contactors) up to 9 contactors) maintenance (A DDC drive can repla

mber of Components Number of Components and fail.

are PartsSpare Parts

Inventory minimized Inventory due to minimized modular due design, to modular commondesign, PCB hardware commonand PCB Inventory hardware minimized Must and stock due directional to modular Must stock contactors, design, directional common speedcontactors, control PCB hardware contactors, speedand control contactor contactors, tips, Must contactor stock directional tips, Programma contactors, sp Spare Parts universal software universal software universal software interface relays,interface and power relays, resistors and power resistors interface relays, and power resistors

oubleshooting Troubleshooting

Built-in diagnostics Built-in helpdiagnostics troubleshoothelp crane troubleshoot performance craneandperformance keep yourBuilt-in system and keep diagnostics your system help troubleshoot crane performance and keep your system No diagnostics available No diagnostics available Troubleshooting up and running up and running up and running

Communicat

No diagnostics available

REDUCED ONGOING REDUCEDMAINTENANCE ONGOING MAINTENANCE EXPENSES AND EXPENSES ENERGY REDUCED AND COSTS ENERGY ONGOING COSTS MAINTENANCE EXPENSES AND ENERGY CO Reverse Pol Solid state design Solid means statenodesign contactor means tips,nocoils, contactor auxiliary tips,contacts, coils, auxiliary Solidcontacts, state design Mustmeans maintain no contactor Must maintain tips, coils, contactor auxiliary tips,contacts, coils, auxiliary mechanical contacts, interlocks, mechanical Must maintain interlocks, contactor tips, coils, aintenanceMaintenance of Components of Components Maintenance ofdirectional Components mechanical interlocks, mechanical directional interlocks, contactors or power contactors resistors or power to replace* resistors mechanical to replace* interlocks, directionaldirectional contactors directional contactors or power contactors orresistors power or power resistorsresistors to replace* directional contactors or powerLoss resis Power

Brakes may be Brakes set at much may be lower set speeds, at muchreducing lower speeds, stress on reducing brake stress parts Brakes while on brake may beparts set while at much lower speeds, reducing stress on brake parts while Normally set at Normally higher speeds set atashigher brakesspeeds are used as brakes to decelerate are usedandto stop decelerate Normally and set atstop higherUndervoltag speeds as bra increasing lining life

ake and Brake Brake Shoe and Brake Life Shoe Lifeincreasing liningincreasing Brakelining andlifeBrake Shoe Life life

ush, Commutator Brush, Commutator and Field and Field Brush, Field Armature currentArmature restricted current toCommutator a maximum restricted of to 200% aand maximum of theofmotor 200%rating, of Armature theand motor a current rating,restricted and a to a maximum of 200% of the motor rating, and a No restrictions with No restrictions DCCP control with DCCP control maximum of 150% maximum of motor of 150% ratedLife field of motor current, ratedCEMF fieldrestricted current, CEMF to 110% maximum restricted to of 110% 150% of motor rated field current, CEMF restricted to 110% ulation Life Insulation Life Insulation

Motor Overl No restrictions with DCCP control

Motorpluggin Contin ock LoadsShock on Mechanical Loads on MechanicalReduces shock loads Shock Loads on Mechanical Reduces on shock mechanical loads power on mechanical train through powersmooth train through speedReduces smoothshock speed Deceleration loads on mechanical control Deceleration through powercontrol plugging train through through and acceleration smooth pluggingspeed and is dependent accelerationonDeceleration is dependentcontrol on through acceleration andacceleration deceleration deceleration acceleration and changing deceleration resistors changing resistors changing resistors wer TrainPower Train Power and Train Emergency State-of-the-art semiconductors State-of-the-art semiconductors regulate motor current regulateand motor reduce current line and State-of-the-art power reduce line semiconductors power regulate motor current and reduce line power DCCP utilizes resistors DCCP utilizes that require resistors additional that require line power additional line powerDCCP utilizes resistors that require a ergy Costs Energy Costs Energy Costs demand resultingdemand in energy resulting savingsin energy savings demand resulting in energy savings Fuse Highly efficient OmniPulse Highly efficient DDC,OmniPulse with low power DDC, with diodelow rectifiers, power diode recovers Highly rectifiers, efficient recovers OmniPulse DDC, with low power diode rectifiers, recovers Substantial energy Substantial lost across energy resistors lost across resistors Substantial energy lost across resisto ergy Recovery/Regeneration Energy Recovery/Regeneration Energy Recovery/Regeneration energy from theenergy load and fromreturns the load it toand thereturns DC supply** it to the DC supply**energy from the load and returns it to the DC supply** IMPROVED SAFETY IMPROVED SAFETY

IMPROVED SAFETY

Motor Groun

Verifies control of Verifies the load. control In hoist of theapplications, load. In hoistmotor applications, armaturemotor circuitVerifies armature is control circuit Requires of isthe load. an additional InRequires hoist applications, collector an additional for redundancy; motor collector armature for capable redundancy; circuitofischecking capable forRequires of checking an additional for collector for r armature continuity Charge Indic

ntinuity Check Continuity at Start Check at Start checked when raise/lower Continuity Check atbefore Startbrake checked when command raise/lower given,command given,released before brake checked released whenarmature raise/lower continuity command armaturegiven, continuity before brake released

otor Series Motor & Field Series & Field ss Detection Loss Detection

Motor Series & Field Series field detection Seriesavailable field detection using aavailable series brake usingona series the hoist, brakebutonnoSeries thecheck hoist, fieldbut detection no check available using Protection feature Protection that provides featurea that fault provides to the drive a fault andtosets thethe drive brake andProtection sets the brake feature that provides a fault to the drive and sets the brake Drive Therm on the armatureon the armature on the armature Loss Detection

ss of Speed LossInput of Speed Input

Loss of speed input Loss could of speed resultinput in skipped could result speedinpoints skippedandspeed high points current Loss and and ofhigh speed current inputand could in s Faultresult History When speed input When isLoss lost, speed theinput driveiswill lost, operate the drive up will to the operate lower up speed to the When inputs. lower speed speed inputinputs. is lost, the drive will operate up to the lower speed inputs. of Speed Input torque transitionstorque transitions torque transitions

ergency Power Emergency LossPower Loss OmniPulse DDC OmniPulse Loss willEmergency shut down DDC and willPower set shutthe down brake andif set DC the power brake is lost if DCwhile OmniPulse power is lost DDCLoad while willcould shut down continue Load andcould with set the acontinue controlled brake ifwith DClower power a controlled ifispower lost while lower is lostifsince powerLoad theis lost couldsince continue the with a contro lowering the load lowering load lowering the load motor is generating motor is generating motor is generating ut Down Shut Down Shutthe Down Ambient Tem Unique to OmniPulse UniqueDDC; to OmniPulse eliminatesDDC; the possibility eliminatesoftheapplying possibility directofUnique DC applying line to direct OmniPulse DC lineDDC; eliminates the possibility of applying direct DC line applicable Not applicable Not applicable lsafe Pre-charge Failsafe Pre-charge Circuit Design Circuitvoltage Design Failsafe Pre-charge Circuit Design voltage to theNot to the capacitor voltage tobank the capacitor bank capacitor bank Altitude

ur-quadrant Four-quadrant Design Design

Efficiently controls Efficiently the motor controls at allthe times motor at all times Four-quadrant Design

Operates in two-quadrants, Operates in two-quadrants, and relies on inefficient and relies on resistors inefficient toOperates resistors in two-quadrants, to and Efficiently controls the motor at all times achieve performance achieve performance achieve performanceHumidity

power resistors *Norequired power except resistorsDBrequired for all hoist exceptapplications DB for all hoist to meet applications industry*No standard to power meet industry and resistors regenstandard required resistorand except depending regen DB resistor foronallpower hoist depending source applications type. on power to meet source industry type. standard and regen resistor depending on power source type. DC supply must**beDCcompatible supply must to realize be compatible energy savings to realizefrom energy regenerative savings from capabilities–consult ** DC regenerative supply must capabilities–consult Magnetek be compatible for more to Magnetek realize information. energy for more savings information. from regenerative capabilities–consult Magnetek for more information.

DC RIVEOMNIPULSE DRIVE DDC DRIVE CIFICATIONS ATIONS GENERAL SPECIFICATIONS SPECIFICATION DESCRIPTION SPECIFICATION POWER

POWER

SPECIFICATION POWER

5-500 HP Horsepower 5-500 HPRange

5-500 HP

30-2000 Amps 30-2000Current Amps Rating Continuous

30-2000 Amps

230-360VDC (standard) 230-360VDC (standard)  6$#OPTIONAL Input 6$#OPTIONAL Voltage -20%/+10% -20%/+10%

230-360VDC (standard)  6$#OPTIONAL -20%/+10%

150% for one minute 150% for one minute Current Overload Capability 200% for three 200% secondsfor three seconds

150% for one minute 200% for three seconds

Single, or Quadruplex Duplex, or Quadruplex nsSingle, Duplex, Motor Circuit Standard Configurations

NTROL I/OCONTROL I/O

Single, Duplex, or Quadruplex

CONTROL I/O

(8) 230VDC (standard); (8) 230VDC other(standard); voltages are other optional voltages are optional (8) 230VDC (standard); other voltages are optional Discrete Control Inputs   6$#OR M!   6$#OR M! Analog Inputs

  6$#OR M!

  6$#OR M!   6$#OR M! Programmable Analog Outputs

  6$#OR M!

 6$# 6$#M!  6$# 6$#M! Programmable Discrete Outputs

 6$# 6$#M!

23  23  Ports Communication

23 

ROTECTION PROTECTION

PROTECTION

Software and hardware Software detection and hardware detection Reverse Polarity

Software and hardware detection

One secondPower ride-through OneLoss second ride-through Capability

One second ride-through

4RIPAT6INWHENSECOND 4RIPAT6INWHENSECOND Undervoltage/Overvoltage

4RIPAT6INWHENSECOND

Electronic time trip Electronic time trip Motor Overload

Electronic time trip

Motor connections Motor are connections verified at the arestart verified of each at the cycle startbefore of each cycleMotor beforeconnections are verified at the start of each cycle before Motor Continuity (Hoist Mode) brake is releasedbrake is released brake is released Standard for hoist Standard applications for hoist applications

Standard for hoist applications Optional for traverse applications

DC Bus Control DC Bus Control Board Interface Board FuseInterface

DC Bus Control Interface Board

king Emergency Power Loss Dynamic Braking Optional for traverse Optional applications for traverse applications

Motor armatureMotor and series armature field detected and seriesforfield hoistdetected applications. for hoist applications. Motor armature and series field detected for hoist applications.

Motor armature Motor detected armature forDetection traverse detected applications. for traverse Tripapplications. level is Trip Motor level isarmature detected for traverse applications. Trip level is bled) Motor Ground (can be disabled) hardware set andhardware non-adjustable. set and non-adjustable.

hardware set and non-adjustable.

Visual indicator Visual on driveindicator unit indicating on drivecharge unit indicating state on charge the state on Visual the indicator on drive unit indicating charge state on the Charge Indicator capacitor bank capacitor bank capacitor bank Heatsink over temperature Heatsink over alarm temperature and shutdown; alarm drive and shutdown; enclosure drive enclosure Heatsink over temperature alarm and shutdown; drive enclosure Drive shutdown Thermal over temperatureover temperature shutdown over temperature shutdown Last 15 faults are Last stored. 15 faults are stored. Fault History

RONMENTAL ENVIRONMENTAL

Last 15 faults are stored.

ENVIRONMENTAL

-10°C to +50°C -10°C (enclosed) to +50°C (enclosed) Ambient Temperature Range

-10°C to +50°C (enclosed)

3300 feet Altitude (1000M) 3300 without feet (1000M) deratingwithout derating

3300 feet (1000M) without derating