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A bout Insul-8 About Insul-8 Corporation Corporation

Your Single Source for Mobile Electrification

Youll find Insul-8 products in use everyday from irrigation systems and manufacturing plants in the heartland of the United States to pubic transportation systems in Malaysia.

Since our inception in 1902, Insul-8 Corporations parent company, Delachaux S.A., has been a leading international presence in the business of providing mobile electrification. As the Delachaux arm in North and South America, Insul-8 Corporation (formerly sister companies Insul-8 and Industrial Electrical Reels, Inc. a.k.a. IER) carries on this tradition of innovation and excellence. Insul-8 and IER became part of the Delachaux Group in 1975 and officially became one company on December 31, 1996. Each company has its own rich history.
Industrial Electric Reels, Inc. began in 1924 with the founding of Industrial Electric Works (IEW), an electrical contractor based in Omaha, Nebraska. After World War II, IEW began the manufacture of electric cable reeling equipment and started IER as an operating division in 1948. IERs first cable reel, the hand rewind Series 102 PORT-O-REEL, was quickly followed by light-duty spring retractable cable reels. IER pioneered the development of cable reeling devices and slip rings. Soon the business expanded to larger, custom built motor driven reels and custom engineered slip rings. IERs reputation spread as a quality manufacturer of reels running the gamut from small commercial duty reels to large custom built reels for the most demanding applications such as container cranes, stacker/reclaimers and bulk material ship loaders and unloaders. Insul-8 products can electrify items from small industrial machinery to large amusement park rides and international public transit systems. Insul-8 Corporation has been a pioneer in providing safety-covered metal conductor systems for the material handling industry since 1944. Insul-8 was the first company to design and produce a stainless steel capped aluminum conductor and the only manufacturer of such a product for almost 20 years.Today, there are over 20 million meters (nearly 12,500 miles) of Insul-8s aluminum/stainless steel contact conductors on container cranes due to the dependability of the bar under the most severe conditions. Insul-8s festoons are known for their safe and efficient operation in which large numbers of conductors can be handled in minimum space. Insul-8 has been in the business of supplying power from stationary sources to mobile systems for the greater part of the 20th Century. Insul-8s cable reels, slip rings, conductor bars, festoon systems and pendants are used in a wide variety of applications ranging from material handling and mass transit systems to water treatment plants and performing arts theaters. In December 1997, after a nine month endeavor, Insul-8 Corporation became ISO 9001 certified for the design and manufacture of our entire line of mobile electrification products in both of our U.S.A. plants in Omaha, Nebraska and Harlan, Iowa.

Insul-8 products are in every industry

Airline Industry Cranes Hangar Doors De-icing Equipment Fuel & Lubrication Rotating Lights Auxiliary Facility Extensions Aluminum Plants Material Handling Repair Facilities Auto Industry Assembly Electric Vehicles Chemical Products Spring & Motor-Driven Cable Reels Hose Reels Slip Rings Conductor Bar Mobile Equipment Shovels Cranes Logging Trucks (Spraying) Cherry Pickers Paper Mills Roll Stands Converting Machinery Products Cable & Hose Spring Reels Conductor Bar Festoon Slip Rings Products Spring & Motor-Driven Cable Reels Slip Rings Conductor Bar Festoon Products Spring & Motor-Driven Cable Reels Conductor Bar Festoon Slip Rings Products Spring & Motor-Driven Cable Reels Conductor Bar Festoon Products Spring & Motor-Driven Cable Reels Hose Reels Conductor Bar Festoon Products Slip Rings Products Motor-Driven Reels Slip Rings Festoon Products Slip Rings Spring & Motor-Driven Cable Reels Products Slip Rings Cable & Hose Spring Reels

Products Spring & Motor-Driven Cable Reels Conductor Bar Slip Rings Products Cable Management Systems Cable & Hose Reels Conductor Bar Products Spring & Motor-Driven Cable Reels Slip Rings Hazardous Location Products Products All Insul-8 Products Products All Insul-8 Products Products All Insul-8 Products Products Conductor Bar Festoon Systems Explosion-Proof Reels Slip Rings Products All Insul-8 Products Products Spring & Motor-Driven Cable Reels Hose Reels Slip rings

Ports Shiploaders Stacker Reclaimers Container Cranes Power Plants

Conveyors Extendible Material Handling Packages, Coal, Ore, etc. Cranes Engineers & Architects Material Handling Government & Military

Railroads

Robots Assembly Lines Sewage & Water Treatment

Theaters & Arenas

Material Handling Systems

Meat Packing

Truck Manufacturers Mobile Manlifts Cherry Pickers Fire Equipment Cranes

Partner in your

we want to be a

success

Contact Insul-8 for all of your

B B F A G K

E L D

H L B B

A B C D

Cord Reels (pg 8) Industrial Duty Cable Reels (pgs 9-11) Motor-Driven Cable Reels (consult factory) Heavy Duty Industrial Hose Reels (pg 18)

Electrification & Pneumatic Needs!

A

J B

K L

M K

E F G H I

Handwound Reels (pg 8) Balance Reels (pg 16) Torque Reels (pg 16) Welding Reels (pg 15) Grounding Reels (pg 17)

J K L M

Slip Rings (pg 33) Conductor Bar (pgs 29-32) Festoon (pgs 21-23) Pendants & Radio Controls(pgs 24-28)

Table of Contents

Cord & Cable Reels . . . . . . . . . . . . . . . . . . . . . . . . . . Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding Reels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Reels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ground Reels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose Reels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crane Information . . . . . . . . . . . . . . . . . . . . . . . . . . . Festoon Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stretch Wire Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pendants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radio Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conductor Bars Kits & Components . . . . . . . . . . . . Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 -12 13-14 15 16 17 18 19 20-22 23 24-26 27-28 29-32 33

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Cable Reel Basics

How To Select The Correct Cable Reel
In order to use the Cable Reel Selection Chart insert, first determine your mechanical, electrical, and cable length requirements. Follow these three steps to make sure you get the best reel for your application needs. Your local representative or the sales team at our factory are glad to help if you need additional assistance.

Step 1 Mechanical Requirements:

How will the reel be used? Stretch, Lift, Drag, or Retrieve? (See below for help.) What type of environment will the reel be located? (Indoors, outdoors, corrosive environment.) What is the Duty Cycle? (How often will the reel payout and retract?) What is the maximum equipment speed? (Maximum recommended speed is 150 feet per minute.) NOTE: For magnet crane applications, please refer to Insul-8s Magnetic Coupler Reels catalog. Catalog No. MAG001.

STRETCH

The cable is stretched horizontally and is unsupported. The reel may be stationary mounted or mounted onto moving equipment. Cable is pulled out by machine. An extra 6%-10% in cable beyond active travel is required for cable sag.

LIFT

Step 2 Electrical Requirements:

(See Determining Cable Requirements for help.) How much amperage is the cable reel expected to handle? At what voltage? What will the reel be required to handle: power or control? How many total conductors are required? (Please include one conductor for dedicated ground.) What gauge (AWG) cable is required? The amperage and total number of conductors required will determine the gauge. (For assistance, please refer to Cable Data Charts.)

The reel needs to lift the cable vertically. The reel is usually stationary. Cable is pulled out of the reel by machine or by hand (as with an overhead lightsource or a pendant station.)

DRAG

Step 3 Cable Length Requirements:

ADD: Active Length: The difference between the minimum and maximum operating payout. PLUS Inactive Length: Cable that always stays out of the reel, even at full retraction. PLUS Safety Wrap: Cable that stays on the reel at maximum payout PLUS Sag Factor (Stretch Only): Add 10% to Active and Inactive Length total. PLUS Lift Height (Drag/Retrieve): The distance between where the cable lays up to the spool center line. Max 4'. PLUS Hook up Length: Cable Required for termination at both ends 2-3' Spool End. High cycles (20K plus), Harsh Environments, etc. May require a different type of cable (consult factory if in question). insul-8.com

The reel needs to drag the cable through supports or along the ground horizontally. The reel is usually stationary. Cable can be pulled out by hand or by machine. Note: This application is the hardest on cable life.

RETRIEVE

The reel needs to pickup (retrieve) the cable.The reel is mounted on moving equipment. Cable is pulled out by machine.

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Cable Data Charts

NOTE: Cable data specific to brand supplied on Insul-8 cable reels. All data based on assembly of Insul-8 Reels with stated cable with 90C conductor temperature. Rating based on an ambient temperature of 30C, derating for a control cable of more than 3 current carrying conductors per NEC and bulk wrap of cable. Nominal diameters and weights shown will vary with different manufacturers. Data derated for cable on reel not retracted. Type SOW-A / SOOW-A Cable, 600 Volts 14 AWG 12 AWG
Weight Lb./Ft. No. Cond. Amps Dia. In. Weight Lb./Ft. No. Cond. Amps Dia. In. Weight Lb./Ft. No. Cond.

16 AWG
No. Cond. Amps Dia. In.

10 AWG
Amps Dia. In. Weight Lb./Ft.

2 3 4

10 10 8

.405 .430 .485

.083 .102 .135

2 3 4

15 15 12

.530 .560 .605

.137 .169 .209

2 3 4

20 20 16

.605 .640 .670

.169 .230 .270

2 3 4

25 25 20

.640 .690 .750

.221 .283 .350

18 AWG
No. Cond. Amps Dia. In. Wt. Lb./Ft.

Type SJOOW/SJEOW Cable, 300 Volts 16 AWG 14 AWG 12 AWG

No. Cond. Amps Dia. In. Wt. Lb/Ft. No. Cond. Amps Dia. In. Wt. Lb./Ft. No. Cond. Amps Dia. In. Wt. Lb./Ft.

10 AWG
No. Cond. Amps Dia. In. Wt. Lb./Ft.

2 3 4

10 10 7

0.285 0.305 0.330

0.046 0.058 0.076

2 3 4

13 13 10

0.310 0.330 0.355

0.056 0.078 0.096

2 3 4

18 18 15

0.340 0.365 0.395

0.076 0.099 0.121

2 3 4

25 25 20

0.410 0.430 0.470

0.113 0.142 0.179

2 3 4

30 30 25

0.545 0.575 0.630

0.185 0.239 0.305

Ampacities are based on 90C insulation all conductors power carrying. Data is for engineering information only. Insul-8 cannot specifically recommend ampacities, since the exact application shall comply with applicable codes.

Cable Characteristics
SJOOW / SJEOW-A
General purpose jacketed cable with fine stranding for flexibility Resistant to oil, water, and weather Suitable for outdoor use 300 volts

SOW-A / SOOW-A
General purpose jacketed cable (larger overall dia. as compared to SJOW-A/SJOOW-A) with fine stranding for flexibility Resistant to oil, water, and weather Suitable for outdoor use 600 volts

Color Code Chart

Cond. No. Base Color Tracer Color Cond. No. Base Color Tracer Color Cond. No. Base Color Tracer Color Wire Size AWG

Welding Cable
AMPS Diameter Inches Weight Lbs./Ft.

*1 *2 *3 *4 5 6 7

Green Black White Red Orange Blue White

Black

8 9 10 11 12 13 14

Red Green Orange Blue Black Red Green

Black Black Black Black White White White

15 16 17 18 19 20 21

Blue Black White Orange Blue Red Orange

White Red Red Red Red Green Green

6 4 2 1 1/0 2/0 3/0 4/0

75 150 225 300 300 450 450 660

.380 .420 .495 .520 .615 .650 .720 .835

.135 .215 .280 .360 .425 .510 .615 .760

() For some reels manufactured in 1997 and prior years 1= Black, 2= White, 3= Red, 4= Green. All others remain the same.

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Economy Series Cord Reels

Economy Hand Rewind Reel
Rugged and lightweight, offers safe and convenient means of handling and storing electric cable, extension cords or wire. For indoor use only. Reel Part Type Number Cable Max. Rating Cable Size Type Length (ft) Accessory Amps Volts
16/3 14/3 12/3 16/3 14/3 12/3 16/3 16/3 14/3 14/3 12/3 16/3 16/3 14/3 14/3 12/3 16/3 16/3 16/3 16/3 14/3 14/3 12/3 SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A SJOW-A 100 200 100 125 100 100 200 100 125 100 100 200 100 200 100 125 100 HSR HSR RB RB RB RB RB 10 15 20 10 15 20 10 10 15 15 20 10 10 15 15 20 10 10 10 10 15 15 20 250 250 250 120 120 120 120 120 120 120 120 250 250 250 250 250 120 120 120 120 120 120 120

1 2

4 5 6

06714-163-0 06714-143-0 06714-123-0 06714-163-0-QB 06714-143-0-QB 06714-123-0-QB 06714-163-1-QB 06714-163-2-QB 06714-143-1-QB 06714-143-2-QB 06714-123-1-QB 06714-163-1 06714-163-2 06714-143-1 06714-143-2 06714-123-1 06714-163-1-H 06714-163-2-H 06714-163-1-R 06714-163-2-R 06714-143-1-R 06714-143-2-R 06714-123-1-R

Type 1

Type 2

Type 3

Type 4

Type 5

Type 6

Notes: 1) Reel types 1 & 2 are without cable. Cable is for reference only. 2) See pages 13 & 14 for specifications on accessories 3) Reel types 2 & 3 are without slip ring, all other types include 120/250V slip ring

Economy Hand Rewind Reel

Indoor/Outdoor Dry Location Use.
Part No. 06716 Description Economy hand rewind reel with 25' 16/3 SJT cord. 4 outlets Weight 3.7 Lbs.

Featuring: High impact polymer housing UL listed for outdoor use

Reel Includes: Cord 25' 16/3 type SJT 4 outlets grounded 115V, 60 Hz Carrying handle molded into case 10 amp circuit breaker

Economy Spring-Driven Cord Reel

Part No. 06715 06715-HSR 06715-FHL 06715-RB3 Description White cord reel w/30' of SJT 16/3 (No Options). UL listed White cord reel w/30' of SJT 16/3 cable and incandescent 75-watt hand lamp (steel guard and hook) with switch and outlet. UL / CSA listed Yellow plastic cord reel w/20' of SJT 18/2 cable and fluorescent 13-watt hand lamp w/switch. UL Listed White cord reel w/30' of SJT 16/3 cable and 3-grounded 10-amp outlets w/ circuit breaker. UL listed Weight 3.7 Lbs. 5.0 Lbs. 4.9 Lbs. 5.0 Lbs.

Note: All Reels have standard Ball Stops & Ratchets that can NOT be de-activated. Featuring: Reel Includes: 9-1/4" x 2" dia. steel housing Feeder cord 2' long with plug Cable guide Locking ratchet UL listed for indoor use Ball stop Hardware for wall or ceiling mount

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1200 Series Industrial Duty Cable Reels

Features
Our 1200 Series POWEREEL is the best built cord and small cable reel on the market today. The price and quality are outstanding. Let Insul-8 put you into a better reel at a better price. UL/CSA listed Reels with SJOW cable rated at 300V (Less Accessory) Reels with SOW-A rated at 600V Finish - Safety yellow powder coated

Reels Include:
Guide Arm- Removable 4 Roller, adjustable to 12 positions for efficient cable storage. Ratchet includes auto locking ratchet for constant tension Adjustable ball stop included 6' feeder cord with 3 prong molded plug All reels come with one conductor grounded to Reel (Example: 3 conductors = 2 live + 1 ground)

(Reel with RB accessory shown) Part Number Size/Cond

121160302511 121160302512 121160302513 121160302514 121160305011 121160305012 121160305013 121160305014 121140303011 121140303012 121140305011 121140305012 121120302511 121120302516 121120302517 121120305011 121120305016 121120305017 122160403011 122140403011 122120405211 16/3 16/3 16/3 16/3 16/3 16/3 16/3 16/3 14/3 14/3 14/3 14/3 12/3 12/3 12/3 12/3 12/3 12/3 16/4 14/4 12/4

Cable Type
SJOW SJOW SJOW SJOW SJOW SJOW SJOW SJOW SJOW SJOW SJOW SJOW SJOW SJOW SJOW SJOW SJOW SJOW SOW-A SOW-A SOW-A

Accessory* NEMA Rating Length (ft)

25 25 25 25 50 50 50 50 30 30 50 50 25 25 25 50 50 50 30 30 30 -RB HSR FLR -RB HSR FLR -RB -RB -RB 100467 -RB 100467 ---4 2 2 2 4 2 2 2 4 2 4 2 4 2 2 4 2 2 4 4 4
13.83 6.25

12.00

4.5

7.75

Notes: 1) * See page 13 for specifica tions on factory installed accessory. 2) All reels weigh approximately 25 lbs. without cable and accessory. 3) NEMA 2 reels are for indoor use, NEMA 4 for outdoor use.

1.63 TYP

2.25 6.70 12.75 (3) Holes for 3/8 Grade 8 Mounting Hardware

1.53

3.25 5.50 Mounting Pattern

3.0

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1400 Series Industrial Duty Cable Reels

Features
Our 1400 Series POWEREEL is an excellent reel for medium to heavy-duty industrial applications. This is our most popular series of reels, suitable for the majority of reel applications. UL listed to US and Canadian safety standards for reels with factory installed cable Ideal for indoor and outdoor use (wet or dry) Weatherproof NEMA 4X slip ring enclosure Heavy all-steel construction Safety-yellow powder-coated finish Numbered terminal blocks for simplified hookup Formed steel stand with multiple mounting holes Guide arm (Removable 4-roller, adjustable to 12 positions for efficient cable storage) Ratchet includes auto locking ratchet for constant tension Available in welding, hose, grounding & torque reel version All reels come with one conductor grounded to REEL (Ex. 3 conductors = 2 live conductor + 1 ground) Ideal for use in: drop lights and boxes, extendable conveyor control cables, overhead hoists, truck cranes, ladder trucks, and utility trucks. Crane class A-C. Available with Type SOW-A or SOOW-A cable installed.
1400 Series Cable Reel Selection Chart (ending 2 digits of part number determine application 11=lift/drag 21=stretch 31=retrieve Cable: AWG / # of Con. 16/3 16/4 14/3 14/4 12/3 12/4 10/3 10/4 Cable Length (NOTE: Actual cable footage installed not active travel) 20 1421603020** 1421604020** 1421403020** 1421404020** 1421203020** 1421204020** 1421003020** 1421004020** 30 1421603030** 1421604030** 1421403030** 1421404030** 1421203030** 1421204030** 1421003030** 1421004030** 40 1421603040** 1421604040** 1421403040** 1421404040** 1421203040** 1421204040** 1421003040** 1421004040** 50 1421603050** 1421604050** 1421403050** 1421404050** 1421203050** 1421204050** 1421003050** 1421004050** 60 1421603060** 1421604060** 1421403060** 1421404060** 1421203060** 1421204060** 1421003060** See 1900 Series 70 1421603070** 1421604070** 1421403070** 1421404070** 1421203070** See 1900 Series See 1900 Series On Page 11 80-125 1421603080** 1421604080** See 1900 Series On Page 11 See 1900 Series On Page 11 See 1900 Series On Page 11

Dimensions
13.5 O.D.

All reels weigh approx. 52 lbs. less cable Contact factory for cable reel requirements not shown in the above selection chart.
C
1.25 3.75

3" & 4.5" Drum Width 6" Drum Width

1.00 Female NPT

Max Dimensions A = 6" B = 8.5" C = 18"

15.00

Note: Mounting pattern for use with pivot base Cat. #PVB.
4.38

6.25

8.25 3.25

3.50 3.88 4.50 5.00 7.13 (8) Holes for 3/8" Grade 8 mtg. bolts 9.25

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1900 Series / 2400 Series Industrial Duty Cable Reels

Features
Our 1900 Series and 2400 Series POWEREELS are your top-quality, low-cost alternatives to other spring reels of higher cable capacity. These reels offer heavy-duty performance at some of the most attractive prices in the market. NEMA 4 Rated & CSA certified Excellent performance in industrial indoor and outdoor applications (wet or dry) Weatherproof slip ring enclosure Heavy all-steel construction Safety-yellow powder-coated finish Standard two-piece roller-guide design for maintainability, with a 345 mounting range Safety-sealed, lifetime lubricated spring motor cannister Generously sized slip ring housing with fully articulating brushes for flawless contact in adverse conditions. Variety of ring amp ratings from 35-150 amps (All reels come with one conductor grounded to reel) ** Reels with (4 or less conductors) are rated at 600 volts, reels with (5 or more conductors) are rated at 250 volt. * For manual operations please request ratchet 40251 when ordering.

Shown: 1900 Series Ideal for use in: utility trucks, overhead cranes and hoists, aviation hangers, automated material handling, large drop lights, receptacle boxes, etc... Ideal for Crane Classes A - C. Reels are sized to handle Type SOW-A,Type W, or Type G cable. For options, please see below. NOTE: Includes 7 feet of extra cable for hookup/safety wrap (Selecting a reel for a 70 foot application will have 77 feet of cable) Stretch reels select next 10 offering to compensate for required 10% cable sag factor.
SO Cable AWG/# con. 16/3 1900/2400 Cable Reel Selection Chart (ending 2 digits of part number determine application 11=lift/drag 21=stretch 31=retrieve 70ft 80ft 90ft 100ft 125ft 150ft 175ft 200ft See 1400 Series On Page 10 See 1400 Series On Page 10 See 1400 Series On Page 10 See 1400 Series On Page 10 See 1400 Series On Page 10 See 1400 Series On Page 10 See 1400 Series On Page 10 192140308011 192140308021 192140308031 192140408011 192140408021 192140408031 192120308011 192120308021 192120308031 192120408011 192120408021 192120408031 192100308011 192100308021 192100308031 192100408011 192100408021 192100408031 192160309011 192160309021 192160309031 192160409011 192160409021 192160409031 192140309011 192140309021 192140309031 192140409011 192140409021 192140409031 192120309011 192120309021 192120309031 192120409011 192120409021 192120409031 192100309011 192100309021 192100309031 192100409011 192100409021 192100409031 192160310011 192160310021 192160310031 192160410011 192160410021 192160410031 192140310011 192140310021 192140310031 192140410011 192140410021 192140410031 192120310011 192120310021 192120310031 192120410011 192120410021 192120410031 192100310011 192100310021 192100310031 192100410011 192100410031 192160312511 242160312521 192160312531 192160412511 242160412521 192160412531 192140312511 242140312521 192140312531 242140412511 242140412521 192140412531 192120312511 242120312521 192120312531 242120412511 242120412531 242100312511 192100312531 242100412511 242100412531 192160315011 242160315021 192160315031 242160415011 242160415021 242160415031 242140315011 192140315031 242140415011 242140415031 192120315011 242120315031

242160317531

242160320031

16/4

242160417531

242160420031

14/3

242140317531

242140320031

14/4

242140417531

242140420031 N/A

12/3

242120317531 N/A

12/4

192120407021 192100307011 192100307021 192100307031 192100407011 192100407021 192100407031

242120415031

242120417531 N/A

10/3

242100315031

242100317531 N/A

10/4

242100415031

242100417531

All reels weigh approx. 112 lbs. less cable Contact factory for cable reel requirements not shown in the above selection chart

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1900 / 2400 Dimensions

Dimensions A through D will vary with selected reel and will be provided with quote.

Accessories
Ball Stops
Type A B B B C C Part No. 34885 34474 34475 34476 34477 34490 For For For For For For cable cable cable cable cable cable Description O.D. ranges O.D. ranges O.D. ranges O.D. ranges O.D. ranges O.D. ranges 0.188 to .438 0.438" to .624" 0.625" to .749" 0.750" to 1.05" 1.06" to 1.38" 1.39" to 1.55"

Type A

Type B

Type C

Cable Grips
Part No. 03622 03623 03624 03625 03626 Cable Cable Cable Cable Cable grip grip grip grip grip for for for for for Description cable cable cable cable cable O.D. ranges O.D. ranges O.D. ranges O.D. ranges O.D. ranges 0.430" to 0.610" 0.611" to 0.740" 0.741" to 0.990" 0.991" to 1.24" 1.25" to 1.49"

Suitable for all Insul-8 Cable Reels

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Accessories
Handlamps
Part No. HSR Description Incandescent Lamp Weight 1.3 lbs.

High impact yellow handle with recessed on/off switch and side 15 amp, 125 volt outlet. All steel, grounded reflector cage with swivel hanger. Accepts up to 14/3 SJOW-A cable. 100-watt bulb not included. UL listed for indoor use.
Part No. FHL Description Fluorescent Lamp Weight 1.2 lbs.

Rubber handle with switch and hanger. Features a plastic non-glare shield with cool operating 13-watt lamp (included). Ballast mounted on feeder cord. *When purchased with reel, ballast is mounted to feeder cord. Also available separately without feeder cord. For use with 16/3 SJOW-A cable only. UL listed for indoor use.

Receptacle Boxes
Part No. RB RB-5-20R 100467 Description Dual 15 amp, 125 volt duplex (4 outlets total) Dual 20 amp, 125 volt duplex (4 outlets total) Single 20 amp, 125 volt duplex (2 outlets) with GFCI

*Receptacle Boxes available with flip covers

Width: 2.5" Height: 4" Depth: 3"

Reel Safe Brake

Available for 1400, 1900, 2400, D, E, F, H & M Series Reels. The Patented REELSAFE brake is a device designed to limit the retraction speed of a spring-powered reel to a speed that will not damage personnel or property should an accidental uncontrolled retraction occur. The REELSAFE is a fully adjustable device. It is preset at the factory to a safe speed but can be adjusted to the users preference after reel installation. Some variation in retraction rate will be noticeable during large temperature variations such as seasonal temperature change and minor adjustments may be desired accordingly.

Patent # 6488224 (For ordering information please contact the factory)

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Accessories
Pivot Bases 1200, 1400, 1900 & 2400 Series
Pivot Bases allow the cable reel to pivot back and forth (<330), for alternate directions of cable payout. Where cable payout exceeds 15 away from parallel to the spool, a pivot base is recomended used. (Note that Swivel Bases are available for applications that require a full 360 continuos rotation.) Pivot Bases are ordered based on the specific style of reel used:

1200 & 1400 Series

Part No. PVB 40274

Description 1200 & 1400 Series Reels 1900 & 2400 Series Reels

Weight 7.5 lbs. 47 lbs.

() Will be assigned at time of order.

1900 & 2400 Series

3600 Electrical Swivel Base

For 1200 & 1400 Series Reels (consult factory for 1900 & larger reels) Swivel bases allow reels to rotate 360O in applications where continuous electrical rotation is required. Insul-8s swivel bases feature completly free running ball bearings in a water / dust tight enclosure. Slip Ring Ratings: 35 amp 600 volt AC.
Part No. 38036 38036B 38036C 38036D 38036E 38036F 38036G Description 3 conductor including ground 4 conductor including ground 5 conductor including ground 6 conductor including ground 8 conductor including ground 10 conductor including ground 12 conductor including ground Overall Height 12.75 12.75 14.25 14.25 15.75 15.75 17.75

Standard Fittings on unit 1.0 NPT for cable 0.50 to .75 O.D. Contact factory for additional fittings for larger size cable.

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1400 & 1900 Welding Reels

Compact, economical and rugged welding reel capable of offering ground. (For welding cable specifications, please refer to Cable Data Chart Pg. 7) 1400 Series Welding Reels are NEMA 4X rated. 1900 Series Welding Reels are NEMA 4 rated. Features: Built to NEC standards Indoor and outdoor use Rugged, all-steel construction Weather-proof design Reels rated at 600 volt 450 amp brushless slip ring Ratchet: positive lock Standard 4-roller guide included 6' feeder cord & ball stop included

1400

Drag Selection Chart

Series 1400 1400 1400 1900 1400 1400 1400 1900 1400 1400 1900 1900 1400 1400 1900 1900 1400 1400 1900 1900 1400 1900 1900 Part Number 145060102511 145060105011 145060107511 195060110011 145040102511 145040105011 145040107511 195040110011 145020102511 145020105011 195020107511 195020110011 145010102511 145010105011 195010107511 195010110011 145100102511 145100105011 195100107511 195100110011 145200105011 195200107511 195000110011 Cable Size (AWG) 6 6 6 6 4 4 4 4 2 2 2 2 1 1 1 1 1/0 1/0 1/0 1/0 2/0 2/0 2/0 Amps Length 25 ft. 50 ft. 75 ft. 100 ft. 25 ft. 50 ft. 75 ft. 100 ft. 25 ft. 50 ft. 75 ft. 100 ft. 25 ft. 50 ft. 75 ft. 100 ft. 25 ft. 50 ft. 75 ft. 100 ft. 50 ft. 75 ft. 100 ft. 95 95 95 95 150 150 150 150 200 200 200 200 250 250 250 250 350 350 350 350 450 450 450

1900

Dimensions
18" 1.25 3.75 A B 3.88 5.00 7.13 1.00 NPT

4.38

3.25

3.25

(8) Holes for 3/8" Mounting Bolts

15

6.25

1400 Series
Max dimensions: A= 6" B= 8.5" C= 18"

1900 Series
Max dimensions: A= 16.7" B= 8" C= 8.2" D= 7.8"

9.25

Maximum dimensions depicted. Detailed drawings available upon request.

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Specialty Torque Reels

1400 Series
Features: Ideal for Indoor and Outdoor Use (wet or dry) Positive lock, constant tension ratchet 12 position adjustable guide arm Formed steel stand with multiple mounting holes Series 1400
14 14 14 14 14 14 14 14 14 14 14 14 14 14 6 6 6 6 6 6 6 6 6 6 6 6 6 6 Model 92 01 050 92 01 120 92 01 050 92 01 120 92 01 090 92 01 050 92 01 040 92 01 090 92 01 040 92 01 050 92 01 050 92 01 050 92 01 040 92 01 040 11 11 11 11 11 11 11 11 11 21 21 21 21 21 Lift Lbs (kg) 5 (2.2) 5 (2.2) 10 (4.5) 10 (4.5) 10 (4.5) 15 (6.8) 15 (6.8) 15 (6.8) 20 (9.0) 20 (9.0) 25 (11.3) 30 (13.6) 30 (13.6) 35 (15.8)

Rubber ball stop and clevis hook included Safety-yellow powder-coated finish Optional 360 swivel base TRPVB for 1400 Series

Series E/F

Range Ft (m) 47 (14.3) 100 (30.5) 30 (9.1) 54 (16.3) 67 (20.4) 12 (3.7) 20 (6.1) 37 (11.3) 9 (2.7) 29 (8.8) 20 (6.1) 12 (3.7) 20 (6.1) 14 (4.3)

Weight Lbs. (kg) 52 (23.6) 65 (29.4) 52 (23.6) 65 (29.4) 65 (29.4) 52 (23.6) 65 (29.4) 52 (23.6) 65 (29.4) 52 (23.6) 65 (29.4) 65 (29.4) 65 (29.4) 52 (23.6)

Maximum Dimensions: 15" H x 9.25" W x 14.50" D

Series E/F
Part # EMZ3TR EMZ4TR FMZ3TR FMZ4TR Lift Lbs (kgs) 27 33 38 45 (12.0) (14.9) (17.2) (20.4) Range Ft (m) 30 (9.1) 40 (12.2) 30 (9.1) 40 (12.2) Weight Lbs (kgs) 78 (36) 100 (46) 100 (46) 122 (56)

Maximum Dimensions: 18" H x 11" W x 17.25" D

Typical Installation

Saddle Clamp
Ideal for push-button pendant applications. Provision is made for fast, simple attachment of cable and pendant station. The model SDI clamp is secured to the cable at the proper location thus providing a strain relief and allowing the cable to hang properly. Use SDI for heavy industrial uses and use SDI14 Series for lighter applications. SDI SDII4 (1400 Series Reel) SDI & SDI14 Series Saddle Clamp
Part # SDI SD114A- SD114B- SD114C- Max. OD Max. OD Max. OD Max. OD Description 1 Cable Saddle Clamp 1-3/8" Cable Saddle Clamp 1" Cable Saddle Clamp 3/4" Cable Saddle Clamp Weight 1 1 1 1 lb. lb. lb. lb.

TORQUE REEL

WIRE ROPE FLEXIBLE CABLE SADDLE CLAMP

LEAD WIRE

ELECTRICAL DEVICE LOWER POSITION

() 02,04,06,08,10,12 represents feet of lead wire from clamp to accessory. insul-8.com

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Specialty Grounding Reels

SDR Series Grounding Reel
Features: NEC standards Rugged all-steel construction Compact design Mounts in any position (with spool perpidicular to Ground/Horizon) Red epoxy coated finish Mounting surfaces are unfinished for maximum electrical contact Resistance not exceeding 0.6 Ohms Compact design SDR Series Grounding Reel includes: Cable: 3/32" diameter stranded steel, air craft type cable with orange nylon coating Grounding clamp: 100 amp; Y version has two 100 amp clamps Auto locking ratchet for constant tension External spring tension adjuster

SDR25

SDR50

Cable Length (ft.) 25' 50' 50' 30' active travel plus 20' ea. branch

Ohms 0.3 0.6 0.6

Description Single Cable Single Cable Y Cable

Part # SDR25-O Orange nylon coated cable SDR50-O Orange nylon coated cable SDR50Y-O Orange nylon coated cable

Weight 8 lbs. 12 lbs. 12 lbs.

H" x W" x D" 6.3" x 5.8" x 3.0" 8.3" x 8.5" x 3.7" 8.3" x 8.5" x 3.7"

1400 Series Grounding Reel

We have pre-configured our rugged 1400 Series POWEREELS for grounding applications by equipping them with the cables listed below.
Cable Length (ft.) 75' 100' 75' 100' Description 12 AWG/1 Cond. SOW-A 12 AWG/1 Cond. SOW-A Orange Nylon Jacket Orange Nylon Jacket

NEMA 4X standards Ball stop included 4 roller guide Auto locking ratchet for constant tension 100 amp grounding clamp included Resistance not exceeding 2 Ohms For drawing see page 15
Part # 142120107511 142120110011 146910107511 146910110011 Weight 52 65 52 65 lbs. lbs. lbs. lbs. H" x W" x D" 14.9" 14.9" 14.9" 14.9" x x x x 13.0" 13.0" 13.0" 13.0" x x x x 13.5" 13.5" 13.5" 13.5"

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1400 Series Heavy Duty Industrial Hose Reels

Why Do You Need a Hose Reel?
Make shop, garage or other work areas safer: A hose left on the ground can be tripped over by employees or customers, potentially causing serious injury. The 1400 Series Hose Reel keeps hose neatly stored and ready to use. Eliminate hose handling problems: Save time and increase efficiency. Grab the hose and go. Its just as easy to reel in. Remember, the 1400 Series hose reel is 100% spring retractable. Extend Hose Life: Save time and money. Reduces costly repair and downtime when hoses are damaged while left on the ground. Series 1400 Hose Reels are designed for 100% unassisted spring retention using direct drive (1:1 ratio) containerized spring motor.These reels will accommodate up to 60' lengths up to 300 PSI Air/Water hose. Reel Features: Durable safety-yellow Indoor/Outdoor use polyurethane powder coating Lifetime lubricated spring Ratchet assembly (easy cartridge disengagement for constant Rugged fabricated steel tension requirements) construction 2 position 4-roller hose guide Ball stop included
Reels to handle 300 PSI Air / Water Hose 20ft/ 6.1m 146250002011 147380002011 147500002011 30ft/9.2m 147250003011 147380003011 147500003011 40ft/12.2m 147250004011 147380004011 147500004011 50ft/15.3m 147250005011 147380005011 Consult Factory 60ft/18.3m 147250006011

Reel Selection Chart

Air Hose ID x OD .25 x .50 .38 x .69 .50 x .88 (MNPT) Fitting Size .25 .38 .50

Hose Specifications
Description: Modified vinyl w/two textile spirals & rubber modified non marking thermoplastic cover
ID in. (mm) .25 (6.4) .38 (9.5) .50 (12.7) OD in. (mm) .50 (12.7) .69 (17.5) .88 (22.4) Braid 1 1 2 Max. working pressure PSI (kg/cm2) 300 (18) 300 (18) 300 (21) Color Blue Blue Blue Weight per 100 Ft. lbs. (kg) 10 (4.5) 17 (7.7) 27 (12.2) Max. available length ft. (approx. m) 112 (34) 112 (34) 112 (34) Min. Bend Radius in. (mm) 3 (76.2) 4 (101.6) 5 (127)
C 13.5 O.D. 1.0

Operating Temp +330F to +1800F +330F to +1800F +330F to +1800F

Dimensions
MAX Dimensions A = 6" B = 8.5" C = 18"
.50 NPT .70 3.75

6.25 15.00 4.38 8.25 3.25

3.88 4.50 5.00 7.13 3.25

(8) holes for 3/8" mounting bolts 9.25

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Understanding Overhead Crane Electrification

Runway Two or more parallel beams upon which the crane operates.Typical types of beams used are S Beam, Wide Flange (either WF or H) or Patented Track Crane Bridge Section of steel beam that is attached to crane end trucks.This section of beam spans the two runway beams and is the running surface upon which the packaged hoist operates. End Trucks Trolley device that consists of four or more rollers which are fitted to operate on the runway beam. Each overhead crane has a minimum of two end trucks to which the crane bridge is attached.

Types of Overhead Cranes

Single Girder, top-running
End truck Crane Bridge

Crane Runway

Double Girder, top-running

Crane Electrification Terms

Runway Electrification For runway power, conductor bars or rails are the main method for supplying power to the crane. Conductor rail system consists of four bars for 3 phase power and one dedicated ground. Conductor bars are mounted from supports that are attached to the crane runway beams. A set of conductor rail collectors are required for each crane operating on the runway beams.These collectors are mounted to the end truck of the crane via a collector mounting staff. For some applications, runway power can be supplied via a festoon system. Cross-bridge Electrification Festoon systems are typically utilized for cross-bridge power and control requirements. The type of festoon system depends on the type of crane, duty cycle of crane, speed of cross-bridge travel and the number of power and control conductors required. Typical set-up requires a track in which the festoon system operates. This track is typically mounted to supports attached to the bridge of the crane.

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Crane Electrification with C-Track Festoon

Typical C-Track Festoon Systems (Power & Control) For Overhead Crane Installation
3 4 5 1 2 6 7 8 9 10

Insul-8 also
offers a Control Trolley with Quick Disconnect plug
11

17

F E S T O O N K I T S

16 15

14 12

13

1 2 3 4 5 6 7 8 9

Fixed End Junction Box Terminal Strips End Clamp Track Hanger Clamp Intermediate Trolley Beam Clamp Cross Arm Support Track
(inside junction box)

10 11 12 13

Control Box Trolley Track Joint Pendant Cable Pendant Push-Button Station or Radio Remote Control Tow Arm Tow Trolley Flat PVC Cable End Stop

Cable Connectors

14 15 16 17

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C-Track Festoon Kits

Pre-configured, standard duty C-Track festoon system kits provide a simple method for ordering complete crossbridge power systems for crane applications. If you need a kit with other cable combinations and trolley styles, just ask us. Kits can also be ordered pre-assembled by simply adding the letter P to the end of the system part number. Example: 36670E = 60' power system 36670EP = 60' pre-assembled power system

For Power Systems

Hanger Clamp

Track

Trolley Mobile End Pigtail

End Stop

End Clamp

Fixed End Pigtail

Loop Depth

Flat Cable

C-Track festoon kit using plastic trolley

14 & 16 AWG - 12 Conductor Systems (#14-4C, #16-8C) Crane Span System Part Number Active Travel (feet) Storage Distance (feet) Weight (lbs) 20' 36670 18.38 1.35 38 30' 36670B 27.84 1.89 45 40' 36670C 37.31 2.43 70 50' 36670D 46.77 2.97 77 60' 36670E 56.5 3.24 102

C-Track festoon kit using steel trolley

Crane Span System Part Number Active Travel (feet) Storage Distance (feet) Weight (lbs) 14 & 16 AWG - 12 Conductor Systems (#14-4C, #16-8C) 20' 30' 40' 50' 36671 18.38 1.35 38 36671B 27.84 1.89 45 36671C 37.31 2.43 70 36671D 46.77 2.97 77 60' 36671E 56.5 3.24 102

Kits include the following: C-track, splices, hangers, anchor hangers, trolleys, tow trolley, end clamp, end stop, flat cable and connectors. Systems are calculated based on a 3 ft loop depth. Cable length supplied includes 10 additional feet for termination purposes. Hanger supports are based on five foot centers. NOTE: For special requirements or individual parts, please contact Insul-8.

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C-Track Festoon Kits

Pre-configured, standard duty C-Track festoon system kits provide a simple method for ordering complete crossbridge control systems for crane applications. If you need a kit with other cable combinations and trolley styles, just ask us. For push-button pendant and drop cable see page 26. Kits can also be ordered pre-assembled by simply adding the letter P to the end of the system part number. Example: 36672 = 20' control system 36672P = 20' pre-assembled control system

For Control Systems

Track

Trolley 12.01 Pendant Trolley

End Stop

End Clamp Fixed End Pigtail

Drip Loop

Loop Depth

Flat Cable

C-Track festoon kit using plastic trolley

16 AWG - 16 Conductor Systems (#16-8C x 2) Crane Span System Part Number Active Travel (feet) Storage Distance (feet) Weight (lbs) 20' 36672 17.08 2.79 43 30' 36672B 26.81 3.06 60 40' 36672C 36.27 3.60 76 50' 36672D 45.73 4.14 93 60' 36672E 55.19 4.68 109

C-Track festoon kit using steel trolley

16 AWG - 16 Conductor Systems (#16-8C x 2) Crane Span System Part Number Active Travel (feet) Storage Distance (feet) Weight (lbs) 20' 36673 17.08 2.79 43 30' 36673B 26.81 3.06 60 40' 36673C 36.27 3.60 76 50' 36673D 45.73 4.14 93 60' 36673E 55.19 4.68 109

Kits include the following: C-track, splices, hangers, anchor hangers, trolleys, 16 pin control trolley with quick disconnect, end clamp, end stops, flat cable and connectors. Systems are calculated based on a 3 ft loop depth. Cable length supplied includes 5 additional feet for termination purposes. Hanger supports are based on five foot centers. NOTE: For special requirements or individual parts, please contact Insul-8.

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Stretched Wire Festoon Kits (aka Tag Line Systems)

Stretched Wire Rope Festoon Systems are well suited for light duty applications where an intermediate support structure is not available. Economical and dependable, stretched wire rope systems provide electrification to small cranes, moving hoists and jib cranes. Load: 20 lbs. max. Per Trolley (2 wheel) Speed: 200 fpm max.
SW 2 SW 6 SW 5 SW 4

Kits include all components listed below: Part #

SW 1 SW 2

Description Nylon Coated Wire Rope, 1/4" dia. Hardware Kit Tow Bar Tow Trolley (2 wheel) Trolley (2 wheel) Anchor Bracket Flat Cable Saddle < 3/4" wide Flat Cable Clip

22950 23288 22830 22828 22826 22836 22834 22835

SW 1 SW 3

SW 3 SW 4 SW 5 SW 6 SW1 14

SW 15

SW 15

For Flat Cable

Kit Part Number Cable O.D. 3/4" Max. 24862 24863 24864 24865 24866 1-3/4" Max. 24867 24868 24869 24870 24871 Max. Span (In Feet) 20 40 60 80 100

SW 14

See page 24 for Flat Cable

No. of Trolleys in Kit 3 6 9 13 17

Load: 20 lbs. max. Per Trolley (2 wheel) 10 lbs. max. Per Trolley (1 wheel)
SW 2 SW 6 SW 10 SW 8

Speed: 200 fpm max.

Kits include all components listed below:
SW 9 SW 7

Part #
SW 1 SW 2 SW 3

Description Nylon Coated Wire Rope 1/4" dia. Hardware Kit Tow Bar Anchor Bracket Tow Trolley (2 wheel) Trolley (1 wheel) *not shown Trolley (2wheel) shown Adapter Cable Clip ( 3/16" to 3/8") Cable Clip ( 3/8" to 9/16") Cable Clip (9/16" to 3/4")

22950 23288 22830 22836 22829 22825 22827 25689 22831 22832 22833

SW 1 SW 3

SW 6 SW 7 SW 8 SW 9 SW 10

SW 11

SW 12

SW 13

SW 11 SW 12 SW 13

For Hose & Round Cable

Kit Part Number Cable/Hose O.D. 3/16" - 3/8" Max. 3/8" - 9/16" Max. 9/16" - 3/4" Max. *1 wheel 2 wheel *1 wheel 2 wheel *1 wheel 2 wheel 24872 25873 24874 24875 24876 24887 24888 24889 24890 24891 24877 24878 24879 24880 24881 24892 24893 24894 24895 24896 24882 24883 24884 24885 24886 24897 24898 24899 24900 24901 Max. Span (In feet) No. of Trolleys in Kit

Contact Factory for Round Cable

20 40 60 80 100

3 6 9 13 17

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Flat Festoon Cable & Connectors

Flat Cable
Required cable length equals track plus 10% plus length required for end connections Cable Part Number Yellow PVC Jacket 23958Y 26550Y 21814Y 26698Y 22542Y 22994Y 21815Y 26005Y 26110Y 22607Y 21813Y 23324Y 31580 31734 31772 Shielded Flat Cable Cable Size Number of Conductors 4 4 4 4 4 4 4 8 8 8 12 12 4 AWG Wire Size #2 #4 #6 #8 #10 #12 #14 #12 #14 #16 #14 #16 #16 Continuous Duty Rating 0 0 at 30 C (86 F) Ambient Amps* 120 90 70 50 40 30 25 21 17 15 17 15 Control Cables No Short Time Rating Short Time Rating Amps** 60 Min. 148 111 83 63 49 36 31 30 Min. 173 130 94 69 52 40 32 No. of Strands per Conductor 665 420 266 168 105 65 41 65 41 65 41 65 65 Weight per Foot (lbs) Nominal Dimensions Unshielded Cable (Inches)= .56 x 1.96 .49 x 1.70 .44 x 1.45 .37 x 1.19 .27 x .88 .23 x .71 .21 x .63 .23 x 1.34 .21 x 1.18 .20 x 1.11 .21 x 1.90 .20 x 1.61 .24 x .76

1.27 .75 .60 .42 .24 .16 .12 .32 .22 .18 .34 .27 .16

* See Current Correction Factors for Temperatures above 300C (860F) ** For Crane and hoist motors in accordance with article 610 of the 1989 National Electric Code for 900C Cables Unshielded cable measurements may vary due to manufacturing tolerances. Contact Insul-8 for shielded cable dimensions. All cables from #10 AWG through #16 AWG have rip cords for easy removal of the outer jacket.

Flat Cable Connectors

For Termination of Cable at Power Source or Junction Box. Construction: Aluminum Body / Rubber Bushing

Catalog
Number 35838 35838B 35837 35835C 35835B 35835 35837B 35837C 35837D 35838C 35838D 35838G 35837E 35837F

No. of Cables 1 1 1 1 1 1 1 1 1 1 1 2 2 2

Cable Size
No. of Cond Wire Size
(AWG)

NPT 2 2 1.5 1 1 1 1.5 1.5 1.5 2 2 2 1.5 1.5

Ref Cable # 26550Y 21814Y 26698Y 22542Y 22994Y 21815Y 26005Y 26110Y 22607Y 21813Y 23324Y 26005Y 26110Y 22607Y

Catalog
Number 35838E 35838F 35837G 35837K 35837J 35837H 35837L 35837M

4 4 4 4 4 4 8 8 8 12 12 8 8 8

#4 #6 #8 #10 #12 #14 #12 #14 #16 #14 #16 #12 #14 #16

No. of Cables 2 2 1 1 1 1 1 1 1 1 2 2

Cable Size
No. of Cond Wire Size
(AWG)

NPT 2 2 1.5 1.5 1.5 1.5 1.5 1.5

Ref Cable # 21813Y 23324Y 22607Y 21815Y 26110Y 21815Y 22607Y 22542Y 26110Y 22542Y 22607Y 22994Y 26110Y 22994Y

12 12 8 4 8 4 8 4 8 4 8 4 8 4

#14 #16 #16 #14 #14 #14 #16 #10 #14 #10 #16 #12 #14 #12

Heat shrinkable connections for single cable and multiple cable groups, for flat and round cable. Corrosion Resistant Flame Retardant Exceeds navy requirements for tightness and integrity when used with one flat cable or multiple flat cables of the same size

Catalog Number 03147 03146 03145

Cable Opening 1.60 1.10 .75

Knockout Diameter 2.00 1.37 1.00

Dimension A 6.17 4.5 4.09

Weight lbs. .40 .10 .06

A Dim

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80 Series Push-Button Pendants

Wide variety for easy customization Two to twelve buttons Compact safety yellow enclosure Single, two and three speeds Neoprene booted buttons Two-piece enclosure simplifies field wiring Soft pressure & positive indent switches/buttons -10O F to 160O F (-15O C to 70O C) operation UL Listed/CUL Listed Contacts rated 5A at 120VAC NEMA 1, 3, 4, 4X, 12 - IP65 enclosure rating 100 g shock resistance Double insulated 2500V withstand voltage

Enclosure Dimensions
90 4.5 DIA.

Number of Positions 2 4 6 8

17.5

A Dim. 4.49 in. (114 mm) 7.09 in. (180 mm) 10.31 in. (262 mm) 12.68 in. (322 mm)

B Dim. 3.07 3.07 3.23 3.23 in. (78 in. (78 in. (82 in. (82 mm) mm) mm) mm)

C Dim. 1.46 in. (37 mm) 1.46 in. (37 mm) 1.48 in. (37.5 mm) 1.48 in. (37.5 mm)
See note

Note: 1) Bushing collar can be mounted facing front or rear 2) For deep enclosure contact your distributor

30

12.5

Part # 34214 34215 34216 34217 34220 34223 34224 34226

Complete Preassembled Pendant Stations 2-Button All One Speed Switches 2 Button All Two Speed Switches 2 Button All Three Speed Switches 4 Button 2 One Speed/Momentary on/off 4 Button 2 Two Speed/Maintained on/off 4 Button All One Speed Switches 4 Button All Two Speed Switches 6 Button 4 One Speed/Momentary on/off

Part # 34227 34232 34235 34236 34237 34238 34239 34241

Complete Preassembled Pendant Stations 6 6 8 8 8 8 8 8 Button Button Button Button Button Button Button Button 4 One Speed/Maintained on/off All One Speed Switches 6 One Speed/Momentary on/off 6 One Speed/Maintained on/off 6 Two Speed/Momentary on/off 6 Two Speed/Maintained on/off 6 Three Speed/Momentary on/off All One Speed Switches

*For switch requirements not shown in the above Selection Chart contact factory.

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60 Series Ergonomic Grip Pendant

Ergonomic comfort design Weighs only 10 oz. Less than 2" wide Made of high-impact ABS resin High visible safety yellow Waterproof NEMA 4 rating Internal and external strain relief Variable diameter cable bushing inlet with clamp Easy to push pressure switches Single speed 5A, 125V contact block

Strain Relief Anchor

Screw w/ Captive lock washer 10.98 (279)

Part # 34211

Description Ergonomic grip 2-button push button pendant

Weight 10 oz.
Recessed Enclosure

Schematic
2.24 (57.00) 1.61 (41.00)

Cable and Accessories

Pendant Control Cable UL & CSA approved 600 volts, 90O F to -10O F (32O C to -23O C) Yellow jacket with A hardness of 75 Excellent resistance to sunlight, oil and water Strain Relief Cable Quality hardware kit used to attach strain relief cable to pendant and junction box Strain relief cable is used to reduce stress to pendant cable Round Pendant Cable with built in Strain Relief UL & CSA Listed Round pendant cable with external strain relief reduces cable stress and strain allowing longer life span of your control cable.

Part # 83092 83093 83094 83095 83096 83097 Part # 83098 83099 34332

Size AWG 16 16 16 16 16 16

Diameter Approx. Net Weight Inches Nom. #1000 Ft. 0.465 145 0.550 200 0.605 255 0.745 375 0.785 455 0.885 540 Description 1/8 dia. nylon steel cable 480 lbs. capacity Hardware kit Includes: 2 thimbles, 4 U-clamps, and an eye bolt S hook hanger Cable OD .52 .58 .63 .76 Weight per 100 Ft. 210 260 330 430

No. of Conductors 8 12 16 24 30 36

Part # 35398 35399 35400 35401 36711

AWG 16 16 16 16

No. of Cond. 8 12 16 24 Hardware Kit

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Radio Controls
ProteanTM Series

Part Number

Transmitter

Description

700PRO4

700PRO6

700PRO8

Protean remote with a stop, start/auxiliary, up and down buttons. The radio is suitable for a single motion (2 direction) and also provides a 2 normally open buttons, a start/ power-on (mainline) connection. The start button also doubles as an additional auxiliary relay. auxiliary button and stop button 701P0004 - Additional Transmitter 701P0040 - Additional Receiver Protean remote with a stop, start/auxiliary, up and down buttons. The radio is suitable for a single motion (4 direction) and also provides a 4 normally open buttons, a start/ power-on (mainline) connection. The start button also auxiliary button and stop button doubles as an additional auxiliary relay. 701P0006 - Additional Transmitter 701P0060 - Additional Receiver Protean remote with a stop, start/ auxiliary, up and down buttons. The radio is suitable for a three motion (6 direction), and also provides a 6 normally open buttons, a start/auxil- power-on (mainline) connection. The start button also iary button and stop button double as an additional auxiliary relay. 701P0008 - Additional Transmitter 701P0080 - Additional Receiver

C Series

Transmitter Specifications
3-stage power indicator Internal alarm Removable key Password power-on option: up to 4 digits Output power < 10mW Response time: 65ms Low power consumption increases battery life Frequency 410-490 MHz, FCC Part 15 Can be programmed directly from receiver on-site Dimensions: 6.24 L x 1.9 W x 1.8 D 4 AA Batteries Relay rated at 10A @ 250VAC and 8A @ 30VDC Easy installation with furnished cable harness Alarm/signal light output option Can be programmed from transmitter on-site Dimensions: 6.125 L x 6.125 W x 3.375 D
Description
3 or 4 motion single speed with 0 to 2 programmable aux. outputs, alarm output, mainline output, and light output. Includes 2 transmitters, receiver, strap, accessories, instructions, alkaline batteries, and legends. 3 or 4 motion 2 speed with 0 to 2 programmable aux. outputs, alarm output, mainline output, and light output. Includes 2 transmitters, receiver, strap, accessories, instructions, alkaline batteries and legends.

Receiver Specifications
Power interruption protection Relay contact failure detector circuit Enhanced watch-dog circuit 3-channel superheterodyne Frequency deviation tracing circuit to compensate for temperature changes Temperature 30 C to 75 C Sensitivity < 110 dBm Adjacent channel rejection > 80dB
Part Number
700DHHC1

Transmitter
Handheld C type 8 button single speed plus E-stop, keyswitch, and On-Off.

700DHHC2

Handheld C type 8 button 2 speed plus E-stop, keyswitch, and On-Off.

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Radio Controls
D Series
Transmitter Specifications
3-stage audible and visual low power warning Internal audible and visual alarm Removable key magnetic (waterproof) Wide selection of pushbutton symbols Shock resistant design impact durability to 50G 4 digit password protection RF output power 10mW Approximate power consumption <32mA Modulation: 2.5KHz; narrow band F.M. External integrated antenna Enhanced watchdog circuit 3 channel superheterodyne FDDI (frequency deviation detection indicator) tracing circuit Sensitivity: to -110dBm Large mushroom E-stop switch 6 AA batteries Programs receiver from ground through RF communication (no need to climb on crane to change frequency or address)

Receiver Specifications
2 programmable modes alarm and signal LED output display Power interruption protection Relays contact failure detection circuit Shock resistant mounting provision, impact durability up to 20G
Part Number
700DHHD1

Adjacent channel restrain >80dB Supply voltage 115/230/380 AC 50/60 Hz 10%

Transmitter
Handheld D type 12 button single speed plus A-B switch, keyswitch, and E-Stop.

Description
Up to 5 motion single speed with 2 to 7 programmable aux. outputs, alarm output, A/B outputs, mainline output, and light output. Includes 2 transmitters, 1 receiver, 2 straps, accessories, instructions, 12 alkaline batteries, 1 spare key, 1 TX-RX interface cable and 2 button legend sheet. Up to 5 motion 2 speeds with 2 to 7 programmable aux. outputs, alarm output, A/B outputs, mainline output, and light output. Includes 2 transmitters, 1 receiver, 2 straps, accessories, instructions, 12 alkaline batteries, 1 spare key, 1 TX-RX interface cable and 2 button legend sheet.

700DHHD2

Handheld D type 12 button two speed plus A-B switch, keyswitch, and E-Stop.

J Series

Transmitter Specifications
3-stage audible and visual low power warning Internal audible and visual alarm Removable key magnetic (waterproof) Wide selection of pushbutton symbols Shock resistant design impact durability to 50G 4 digit password protection RF output power 10mW Approximate power consumption <32mA Modulation 2.5KHz; narrow band F.M. Large mushroom E-stop switch 4 AA batteries Internal antenna Programs receiver from ground through RF communication (no need to climb on crane to change frequency or address) Two dual axis joysticks A-Both-B selector Adjacent channel restrain >80dB Supply voltage 115/230/380 AC 50/60 Hz 10% Signal alarm, light and E-stop button included on front cover

Receiver Specifications
2 programmable modes alarm and signal LED output display Power interruption protection Relays contact failure detection circuit Shock resistant mounting provision, impact durability up to 20G
Part Number
700DBMJ5

External integrated antenna Enhanced watchdog circuit 3 channel superheterodyne FDDI (frequency deviation detection indicator) tracing circuit Sensitivity to -110dBm

Transmitter
Dual joystick type J, 5 speed plus E-stop, keyswitch, 2 selectors, and 2 pushbuttons.

Description
Up to 8 motions through use of A-Both-B switches, 2-4 programmable aux. outputs, mainline output, and light output. Includes 2 transmitters, 1 receiver, 2 straps, accessories, instructions, 8 alkaline batteries 1 spare key, 1 TX-RX interface cable and 2 button legend sheets.

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Safe-Lec 2 V-Contact Conductor Bar

Safe-Lec 2 crane electrification is used to power hoist, trolley and bridge motors for overhead cranes, monorails, jib and gantry cranes. To choose the proper kit, find the conductor bar group with the required amperage. Pick the length required from within that group. Choose the bracket style desired. Systems with web brackets will have a WEB suffix. Systems with flange brackets will have an FLG suffix. (Flange bracket shown) Kits include all necessary conductor bar, hangers, brackets, power feeds, and end covers for a 4-conductor system with one as a dedicated ground. Collectors and collector mounting staff are included for one vehicle.

Kit P/N 37355A-WEB 37355A-FLG 37355B-WEB 37355B-FLG 37355C-WEB 37355C-FLG 37355D-WEB 37355D-FLG 37355E-WEB 37355E-FLG 37356A-WEB 37356A-FLG 37356B-WEB 37356B-FLG 37356C-WEB 37356C-FLG 37356D-WEB 37356D-FLG 37356E-WEB 37356E-FLG 37357A-WEB 37357A-FLG 37357B-WEB 37357B-FLG 37357C-WEB 37357C-FLG 37357D-WEB 37357D-FLG 37357E-WEB 37357E-FLG 37358A-WEB 37358A-FLG 37358B-WEB 37358B-FLG 37358C-WEB 37358C-FLG 37358D-WEB 37358D-FLG 37358E-WEB 37358E-FLG

Length of System 9m / 29.8ft 9m / 29.8ft 18m / 59.6ft 18m / 59.6ft 27m / 89.4ft 27m / 89.4ft 36m / 119.2ft 36m / 119.2ft 45m / 149ft 45m / 149ft 9m / 29.8ft 9m / 29.8ft 18m / 59.6ft 18m / 59.6ft 27m / 89.4ft 27m / 89.4ft 36m / 119.2ft 36m / 119.2ft 45m / 149ft 45m / 149ft 9m / 29.8ft 9m / 29.8ft 18m / 59.6ft 18m / 59.6ft 27m / 89.4ft 27m / 89.4ft 36m / 119.2ft 36m / 119.2ft 45m / 149ft 45m / 149ft 9m / 29.8ft 9m / 29.8ft 18m / 59.6ft 18m / 59.6ft 27m / 89.4ft 27m / 89.4ft 36m / 119.2ft 36m / 119.2ft 45m / 149ft 45m / 149ft

310001 310101 60A 100A Bar* Bar* 8 8 16 16 24 24 32 32 40 40 8 8 16 16 24 24 32 32 40 40

310301 160A Bar*

310401 310872 250A Steel Bar* Joint 4 4 12 12 20 20 28 28 36 36 4 4 12 12 20 20 28 28 36 36

310873 Copper Joint

310850 310910 310892 Joint Power End Cover Feed Cover 4 8 4 8 8 4 8 8 4 8 16 4 8 16 4 8 24 4 8 24 4 8 32 4 8 32 4 8 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8

310984 Web Bracket 6 12

310980 Flange Bracket 6 12

310985 Beam Clamp 12 24 36 48 60

18 18 24 24 30 30 6 6 12 12 18 18 24 24 30 30 6 6 12 12 18 18 24 24 30 30 6 6 12 12 18 18 24 24 30 30 60 48 36 24 12 60 48 36 24 12 60 48 36 24 12

310821 310832 4-Pole Anchor Hanger Clamp 5 4 5 4 11 4 11 4 17 4 17 4 23 4 23 4 29 4 29 4 5 5 11 11 17 17 23 23 29 29 5 5 11 11 17 17 23 23 29 29 5 5 11 11 17 17 23 23 29 29 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4

310990 100A Coll* 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8

310991 310992 Coll Dbl. Coll Staff Staff 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

60 AMP

8 8 16 16 24 24 32 32 4 4 12 12 20 20 28 28 36 36

100 AMP

8 8 16 16 24 24 32 32 40 40 8 8 16 16 24 24 32 32 40 40

8 8 16 16 24 24 32 32

160 AMP

4 4 12 12 20 20 28 28 36 36

8 8 16 16 24 24 32 32

250 AMP

Parts of each kit can be purchased separately see price book *Quantity shown includes necessary ground conductors and collectors

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Safe-Lec 2 V-Contact Conductor Bar

Typical 3-Phase Runway
Minimum Conductor Spacing Single or multiconductor hangers 43mm (1.7") Insulated Hangers 60mm (2.36")

.75M (29.5") Max.

450mm (18") Recommended Minimum 150mm (6")

150mm (6") Minimum Anchor Point

Hanger End Cover

1.5M (59") Recommended Hanger Spacing Vertical Entry For Curves For Lateral Entry 1.125M (44.3")

Joint Powerfeed End Cover Conductor Section 4.5M (14'-9")

Basic Safe-Lec 2 V-Contact Components

INSULATED CONDUCTOR BAR
Length: 4.5 meters (14' 9")
Description Standard Phase Cover (Orange) Standard Ground Cover (Green) 60 Amp Steel 100 Amp Steel 160 AmpCopper 250 Amp Copper Part No. Part No. Part No. Part No. 310001 310002 310101 310102 310301 310302 310401 310402

END COVER
Description Steel / Copper Part No. 310892

Weight: 0.020kg (0.044lb)

26.2 mm (1.03")

22.3 mm (0.88")

68mm (2.68")

JOINT COVER
Description Part No. Standard Phase 310850 Standard Ground 310851 Weight: 0.027kg (0.060lb)
13.6mm (0.54)

31mm (1.22")
50m m( ") 1.97

121.4 mm (4.78")

Description Steel Joint Copper Joint

Part No. 310872 310873

Weight 0.401kg (0.904lb) 0.440kg (0.970lb)

43mm (1.69")

23 (0. mm 88 ")

COPPER AND STEEL JOINTS

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Basic Safe-Lec 2 V-Contact Components

POWERFEED AND COVER
Part No. 310910 Up to 250 Amp

4-POLE HANGER
Part No. 310821

40 mm (1.57")

230 mm (9.06")

SINGLE-SIDED FLANGE BRACKET 402.5MM (15.8")

Flange Width = 3.25"- 6"

108 mm (4.25")

BEAM CLAMP STANDARD MOUNT WEB BRACKET

Part No. 310980

Part No. 310984

Two (2) beam clamps required per flange bracket.

Part No. 310985 Weight: 0.106kg (0.234lb)

SINGLE COLLECTOR BRACKET Length: 400mm (16")

Part No. 310991

100 AMP COLLECTOR

Part No. 310990 (Red) 399355 (Green)
Customer Supplied Cable

DOUBLE COLLECTOR BRACKET Length: 400mm (16")

Part No. 310992

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Basic 8-Bar Components

Hanger Clamp Power Feed End Cover 8-Bar Conductor

1" Square Bar Collector

1) Conductor Bar The supply of incoming power. 2) Powerfeed Attachment of incoming power. 3) Collector Collects the incoming power and forwards to machine. 4) Hangers Supports the conductor bar.

5) End Cover Safety protection at the end of conductor system. 6) Brackets Supporting device for attachment of multiple hangers. 7) Anchor Clamp Supporting device for directing movement during thermal expansion and contraction.

8 Bar/Conductor Bar Replacement Components

CONDUCTOR BAR WEB BRACKET HANGER
Part 22135 11000 11008 13601 Description 90A Bar 110A Bar 250A Bar Joint Cover End Cap Power Feed Plastic Hanger Cross Bolt Hanger Anchor Clamp 30A Coll H 30A Coll C 100A Coll C 100A Coll H Web Bracket

JOINT COVER

ANCHOR CLAMP END COVER

11088 11091 22800 11076 21833 13131 13128

COLLECTOR

POWERFEED

13613 13629 22014

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Insul-8 Slip Rings

Insul-8 Slip Rings allow electrical power and control signals to pass from a stationary source to a rotating machine member. All rings are machined copper alloy, finely polished for maximum wearability and contact area. Brushes are copper graphite. Enclosed versions are housed in NEMA 4 rated painted steel enclosures, with shaft and mounting flange included. Maximum Speed: 125 rpm. The chart below is a small representation of the hundreds of ring styles we build. We can also quote silver-plated ring sets for low signal applications, and ampacities from 5 amps all the way up to 1200 amps, in bore sizes from 3/4" all the way up 40"! We have dozens of different enclosure styles and options available to suit any industrial application. Give us a call with your application!
1.5" Bore Assys RA-D04 RA-D04B04 RA-D04B08 RA-D04B12 RA-D04B16 RA-E04 RA-E04B04 RA-E04B08 RA-E04B12 RA-E04B16 Same Ring in RU Style Enclosure RAR-D04 RAR-D04B04 RAR-D04B08 RAR-D04B12 RAR-D04B16 RAR-E04 RAR-E04B04 RAR-E04B08 RAR-E04B12 RAR-E04B16 Ring Specs 4 rings 35 amp/600 volts 4 rings 35 amp/600 volts, plus 4 rings 15 amp/250 volts 4 rings 35 amp/600 volts, plus 8 rings 15 amp/250 volts 4 rings 35 amp/600 volts, plus 12 rings 15 amp/250 volts 4 rings 35 amp/600 volts, plus 16 rings 15 amp/250 volts 4 rings 75 amp/600 volts 4 rings 75 amp/600 volts, plus 4 rings 15 amp/250 volts 4 rings 75 amp/600 volts, plus 8 rings 15 amp/250 volts 4 rings 75 amp/600 volts, plus 12 rings 15 amp/250 volts 4 rings 75 amp/600 volts, plus 16 rings 15 amp/250 volts

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Notes Page

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Solutions from a Single Source

ISO 9001 Certified

SPRING DRIVEN REELS

SLIP RINGS

FESTOON

CONDUCTOR BAR

Distributed By:

PUSH BUTTON PENDANTS Please visit our website at:

CONDUCTOR BAR

www.insul-8.com

CANADA
175 Boulevard J.F. Kennedy St. Jerome, Quebec J7Y 4B5 Phone: (450) 565-9900 Toll Free: (800) 667-2487 Fax: (450) 432-6985
e-mail: contact@insul-8.com

USA
10102 F Street Omaha, NE 68127 Phone: (402) 339-9300 Toll Free: (800) 521-4888 Fax: (402) 339-9627
e-mail: i8-info@insul-8.com

AUSTRALIA:
14 England Street Dandenong, Victoria 3175 Phone: (3) 9706 88 44 Fax: (3) 794 92 98
e-mail: insul8@peninsula.starway.net.au

CAT8006 10/02