Magpowr

In 1968, a small company outside of St. Louis, Missouri, called Magnetic Power Systems (now Magpowr) pioneered the use of magnetic particle torque control technology for industrial applications. For more than 45 years, they have led the tension control industry by engineering controls, sensors and torque devices for all types of tension control applications that consistently deliver results.

Tension and Torque Controls

    Cygnus Tension Control
  • Cygnus Tension Control

    A variety of advanced yet easy-to-use features are apparent immediately to operators using MAGPOWR’s compact, powerful Cygnus® Tension Controls. Operators can easily navigate through advanced tension control functions and codes using on-screen prompts displayed in full text, making the setup process faster. Web tension is maintained or adjusted using multifunction “smart keys,” similar to those used in ATMs, and a large backlit display for easy viewing. Converters and printers can dramatically reduce setup time and improve consistency with powerful features like automatic tuning and out of round roll compensation (previously only possible with a dancer control). Complex tension settings can be input quickly with full text prompts as opposed to more complicated input procedures of the past.

    • Web Break Detection
    • Out-of-Round Roll Compensation
    • Bus Communication Capability
    • Auto Tuning
    • Weightless Load Cell Calibration
    • Advanced Load Cell Diagnostics
    • Gain Scheduling
    • UL and CE Approved

     

    Closed Loop Control; small, powerful and feature-rich

  • VERSATEC Tension Control
  • VERSATEC Tension Control

    MAGPOWR’s VERSATEC Versatile Tension Control provides true ease of use and extreme flexibility with its wide range of functions and operating modes. The VERSATEC Versatile Tension Control is a multi-function automatic tension or process controller that uses the US-2 Ultrasonic Sensor to measure distance and roll diameter. It has selectable operating modes for Unwind, Rewind, Dancer, Free Loop, or Ranging applications. This flexibility eliminates the need to learn the operation of different controls for different tension zones.

    All setup and operating screens on the VERSATEC unit are indicated directly on the multi-line alphanumeric menu driven display in real words, not codes, with the corresponding values or status. From the keypad and display, you can control all operating parameters for any operating mode, including tension, distance, dancer position, loop position, alarm set points, security, language and units, and setup selection.

    • Unwind, Rewind, Dancer, Free Loop and Ranger Control all in one package
    • Stores four setups for quick, precise changeovers
    • Language selectable in English, French, German, Italian or Spanish
    • Selectable inch or metric units of measurement
    • 4-20MA, 0 to 10VDC, -10 to +10 VDC outputs all standard
    • Accepts remote inputs from a PLC or remotely mounted push buttons to adjust tension setpoint or change operating setup
    • Can be used to control magnetic particle and pneumatic clutches and brakes, or AC and DC drives
    • Available in Dancer Control, Free Loop, and Ranger control modes

    A multi-function automatic tension or process controller

  • Spyder Plus Tension Control
  • Spyder Plus Tension Control

    Designed for precise tension control, MAGPOWR’s cost-effective Spyder Tension Control is capable of controlling web tension in closed-loop, open-loop, unwind, rewind, point-to-point or dancer applications. It measures tension from one or more MAGPOWR load cells and outputs a corrective analog signal to control a torque device. Its reduced size means it can be hidden away in an enclosure or underneath the machine.

    With its Ethernet connection, the easy-to-use Spyder can be viewed on a web browser for remote troubleshooting, programming and/or data collection. Additionally, the Spyder provides an analog input for Manual Level setpoint, control inputs for Run/Stop, Auto/Manual: Tension On/Off, and E-Stop, and a 0-1 mADC meter output proportional to measured tension.

    Spyder Plus has the ability to control open loop applications, advanced features for dancer applications, and the ability to interface and share data remotely. Spyder Plus now has powerful features for dancer applications that were once only available with more expensive controls. Dancer mode now allows the unique ability to use load cells to monitor web tension, while remote setpoint adjustment improves efficiency, especially when multiple controls are used in the same application. Spyder Plus also works with third party ultrasonic or laser sensors to determine roll diameter.

    • Powerful tension control at an affordable price used to control clutches and brakes, or interface directly with a drive
    • Troubleshooting and parameter access via a web browser
    • Share data remotely with a PLC or remote PC via Ethernet with Modbus/TCP
    • Advanced features for Dancer applications including Dancer Mode and Remote Setpoint Adjustment
    • Adjustable taper tension
    • User-friendly keypad and display
    • Versatile control for unwind, rewind, point-to-point or dancer applications
    • Compatible with any 3rd party ultrasonic or laser sensor (0 to 10 Vdc signal required)
    • UL and CE Approved

     Compact, cost-effective tension control for unwind, rewind, point-to-point or dancer applications

     

  • Spyder Plus S1
  • Spyder Plus S1

    The Spyder Plus S1 tension controller has all the existing features of the Spyder Plus controller, while adding an additional input for roll diameter. This input allows for additional powerful features normally reserved for our highest end controllers.

    By referencing the actual measured diameter on this new input, this DIN rail mounted low-cost controller now includes very precise taper tension, hold level change options and inertia compensation options in load cell and dancer modes. In addition, gain compensation in dancer mode allows for a stable dancer from full roll to core, regardless of roll-build ratio.

    Like the Spyder Plus, the Spyder Plus S1 is a controller that can be configured as an open loop, closed loop load cell or closed loop dancer modes, providing accurate, reliable control by providing feedback to clutches and brakes, or interfacing directly with drives in unwind, rewind or point-to-point applications.

    Built in Modbus TCP communications provide the ability to easily interface and share data with an existing PLC, remote PC, HMI or web browser, allowing for remote set point adjustment to further improve efficiency, especially when multiple controls are used in the same process.

    • Powerful tension control at an affordable price
    • Open Loop, Closed Loop Load Cell and Closed Loop Dancer control in one package
    • Diameter input for precise and adjustable taper tension, dancer gain compensation, advanced inertia compensation and hold level options
    • Parameter access at keypad or via built in Modbus/TCP or web browser
    • Used to control magnetic particle or pneumatic clutches and brakes, or interface directly with drives

     

  • Dancer / Follower Arm Control
  • Dancer / Follower Arm Control

    Need control of a dancer, follower arm or both? No problem, as MAGPOWR’s DFC-90 and DFC-A low-cost tension controls can handle either operation mode.

    Dancer Mode: The DFC-90 and DFC-A are full PID closed-loop dancer controls, controlling web tension by sensing the position of the dancer arm through a DFP or DFP-2 Position Sensor and adjusting the clutch, brake or motor control torque accordingly to maintain the dancer position set point.

    Follower Arm Mode: The DFC-90 and DFC-A control web tension by compensating for measured changes in the roll diameter. Roll diameter changes are measured through the DFP or DFP-2 Position Sensor and a follower arm. An optional Stop Multiplier provides additional stopping torque to help stop large unwind rolls.

    • Superior control performance at an affordable price
    • Enhanced dancer algorithm and tuning method for performance
    • Non-interactive Core and Full Roll adjustments
    • Compact enclosure requires minimal space
    • Simplicity of DIN rail mounting
    • UL and CE Approved for safety and electrical noise immunity
    • Applications:
    • DFC-90: Dancer or Follower Arm Control of a magnetic particle clutch or brake
    • DFC-A: Dancer or Follower Arm Control of a pneumatic brake, clutch or motor drive

    Low-cost tension control for Dancer or Follower Arm applications

     

  • TC-5 Power Supply
  • TC-5 Power Supply

    Dependable current-regulated power supplies are imperative for the proper operation of all magnetic particle clutches and brakes, and MAGPOWR’s are no different. The MAGPOWR TC-5 is a solid state current regulated 90 VDC power supply. It has four current ranges of 1/8, 1/4, 1/2 and 1 amp, selected by a simple jumper on the circuit board. This unit also includes reverse current circuitry as a standard feature, thus allowing greater controllability in the lowest torque range of the clutch or brake being operated.
    The TC-5 is easy to work with, as the front panel meter indicates the current output and automatically reads full scale for each current range selected. The operator controls the output by rotating the front panel potentiometer.

    • Four current ranges for flexibility
    • Enclosure mounted (TC-5) or front panel mounted (TC-5P) models available
    • Reverse current circuitry provides greater control in low-torque applications
    • Operates MAGPOWR Magnetic Particle Brakes and Clutches with 90 VDC coils
    • Reverse current for greater controllability in low-torque range applications

    For use with Magnetic Particle Clutches and Brakes

     

  • PS-24 and PS-90 Power Supply
  • PS-24 and PS-90 Power Supply

    Complete control is the goal of any operation utilizing brakes and clutches. MAGPOWR’s PS-24 & PS-90 Power Supplies provide a small amount of reverse current circuitry as a standard feature to minimize the drag torque of a clutch/brake, allowing greater controllability in the lowest torque range.

    These power supply units control any size MAGPOWR clutch or brake with optimum resolution. MAGPOWR’s current-regulated power supplies are used for the control of magnetic particle clutches and brakes in unwind, rewind, or intermediate tension control applications. With selectable current ranges, these compact enclosures can be mounted inside the machine cabinet, allowing your operator to adjust torque through a remotely mounted potentiometer or with a 0 to 10 vdc control signal from MAGPOWR Open Loop and Closed Loop controllers, or any control device like a computer or PLC.

    • Provides control for a magnetic particle clutch or brake
    • Current regulated output in selectable ranges
    • Manually adjusts through a remotely mounted potentiometer or automatic controller
    • Compact enclosure requires minimal space
    • Conveniently mounts inside the Cygnus-E enclosure
    • UL and CE Approved
    • Simplicity of DIN rail mounting

    For current regulated power to Magnetic Particle Clutches and Brakes

     

Load Cells

    TS Load Cells
  • TS Load Cells

    TS Load Cells provide the most consistent control of tension, no matter how the temperature changes throughout the day. In fact, all MAGPOWR Load Cells are designed with foil strain gauges that provide the lowest temperature drift rating possible (.02% per º C), which can mean the difference between a profitable web and a floor of wasted material.

    These rugged load cells are extremely accurate devices used to measure tension in any unwind, rewind or intermediate web processing application. The unique low profile design minimizes space requirements inside the machine frames, thus maximizing the potential for web width. TS load cells are designed with mechanical overload stops in both force directions to eliminate sensor damage and the need to recalibrate even after extreme overloads, while also offering the flexibility of a variety of mounting styles and coupling options.

    Split coupling models
    Load Cells with Split Couplings can be used to measure web tension through dead-shaft or live-shaft idler rolls. With one load cell mounted to each side of the machine frame, the idler roll is supported between the two load cells. The resultant force of the web tension is measured as a load on the roll by the load cells.
    The Split Coupling allows the idler roll to be easily installed after the load cells have been mounted to the machine frames. The coupling design also accommodates misalignment between the machine frames and allows for thermal expansion of the idler roll shaft during machine operation. The unique coupling design also allows its use in both dead-shaft and live-shaft applications.

    In-roll coupling models
    The In-Roll Coupling is designed to insert directly into the end of an idler roll. With one load cell mounted to each side of the machine frame, the idler roll is supported between the two load cells. The resultant force of the web tension is measured as a load on the roll by the load cells.
    The In-Roll Coupling includes a spherical bearing to allow for smooth rotation of the idler roll and to accommodate misalignment between the machine frames. This coupling type eliminates the need for idler rolls with shafts and bearings, thus reducing the overall cost of the tension sensing system.

    Wire pulley models
    The Wire Pulley is used for single strand applications for any kind of material. When mounted to the side of a machine frame or bracket, a load cell measures tension in the strand as it passes over the nickel plated aluminum load cell pulley.

    • Low profile design allows maximum web widths
    • Multiple mounting options for maximum flexibility
    • Three coupling styles for use with any type idler roll
    • Ruggedly constructed for long life and dependability
    • Mechanical overload stops for protection even under severe overloads
    • Full Wheatstone bridge design for measurement accuracy
    • Inch and Metric models for international installations
    • Load cell mounting styles available: Stud Mount, Pillow Block, or Flange Mount

    Split Coupling, In-Roll, and Wire Pulley Models

     

  • GTS Load Cells
  • GTS Load Cells

    The stability and accuracy displayed by MAGPOWR’s GTS Global Load Cell allow the tension to be precisely measured and controlled on a roll. The GTS units, designed to be mounted under standard inch or metric pillow block bearings, measure the load created by the web and acting on the sensing roll.

    Two GTS Load Cells should be used, one for each side of the sensing roll, thereby accurately measuring the total web tension force acting on the roll, independent of web width or location. The flexible cable connector eliminates the need for left and right models, as each GTS load cell can be mounted on either side of the machine.

    A full Wheatstone bridge is incorporated into each GTS load cell for the maximum accuracy and stability. All sizes are adaptable and pre-drilled and tapped to accept standard inch and metric pillow block bearings.

    • Ready for Installation – pre-drilled to accept Inch or Metric pillow block bearings
    • Accurate – full Wheatstone bridge maintains the optimum accuracy and stability
    • Rugged – unitized construction for long lasting performance
    • Compatible with all MAGPOWR tension readouts and controls
    • Adaptable – t-slot and blank plate mounting adapters are available to suit many configurations
    • Reliable – positive overload stops prevent load cell damage
    • UL and CE Approved

    Stable and accurate for light to heavy-duty applications

     

     

  • CL Cantilevered Load Cells
  • CL Cantilevered Load Cells

    Load cells are not where operators want to spend their money. MAGPOWR’s CL Cantilever Load Cells facilitate that as they are the most cost effective cantilever load cell on the market. These sensors have the unique ability to accept virtually any roll and shaft assembly. Operators are no longer restricted in design – they simply install one of their spare roll assemblies into the Model CL Load Cell.

    MAGPOWR’s CL Cantilever Load Cells are designed to support cantilevered idler rolls in processing machines that have just one side frame. They then accurately measure and control tension in a narrow moving web and are typically used on paper, film, foil, wire, fiber, fabrics or any materials used in the label, tag, tape, printing or converting industry.

    These rugged load cells have mechanical overload stops and can be mounted inside or outside of the machine frame.

    • Inside or outside machine mounting
    • Rugged construction for long-life
    • Built-in mechanical stops
    • IP67 rated for water wash-down & immersion

    Accurate measurement of web tension on cantilevered idler rolls

     

  • TLC Thin Load Cell Series
  • TLC Thin Load Cell Series

    The MAGPOWR TLC load cells are extremely accurate devices used to measure web tension in any unwind, rewind or intermediate web processing application. Delivering precise web tension with low temperature drift due to a full Wheatstone bridge construction, the load cells allow for force measurement and 10 times overload protection in both force directions.

    With a low profile design, space between the machine frames dedicated to the load cell is minimized. The load cells can also be mounted on the outside of the machine frames, eliminating any space required for the load cells.

    • Used in live shaft applications
    • Standard in metric models
    • Flange and pillow block mounting
    • Four load ratings from 50 to 500 newtons (11 to 112 pounds) in size A, four load ratings from 500 to 3000 newtons (112 to 675 pounds) in size B
    • Ruggedly constructed for long life and dependability
    • Mechanical overload stops for 10x protection under severe overloads
    • Full Wheatstone bridge design for measurement accuracy and low temperature drift
    • Can be mounted on the inside of machine frames or hidden on the backside of the machine frames
    • Size A can be mounted using three bolts on a 90 mm bolt circle or four bolts on a 75 mm bolt circle
    • Size B can be mounted using three bolts on a 150 mm bolt circle or four bolts on a 135 mm bolt circle

    MAGPOWR Thin Load Cell, Size A and B

     

  • LC-500G Low Tension Load Cells
  • LC-500G Low Tension Load Cells

    Lightweight single strand applications including wire, fiber optics and filament textiles face the requirements of tension measurement. For various reasons, lighter, thinner, finer materials are now demanded, and manufacturers require tension controls that can help facilitate those demands.

    MAGPOWR’s Low Tension Load Cells (LC-500G & LC-500GS1) have full wheatstone bridge strain gage configurations, and the meet the same industry leading specifications as all other MAGPOWR load cells. The LC-500G, designed to mount easily into almost any single strand installation, also employs 360 degrees of overload protection preventing the need for recalibration in the event of overload situations. For applications requiring special pulleys, the LC-500GS1 is available with provisions for a customer-supplied pulley.

    • Full Wheatstone bridge strain gauge configuration for reliable operation
    • 360 degree overload protection
    • Mounts easily into almost any single strand application

     

    500 gram load cells for wire, filament and textiles

  • TSU Under Pillow Block Load Cells
  • TSU Under Pillow Block Load Cells

    Ruggedly constructed to stand up to mill duty and with built-in mechanical overload stops in both force directions, MAGPOWR’s TSU Under Pillow Block Load Cells can be bolted under your present roll support bearings and they will accurately measure the tension forces on the machine sensing the roll created by the web. It can display and control the web tension through MAGPOWR tension readouts and controls.

    The TSU is best used with two load cells, one under each pillow block bearing that supports the sensing roll, which then will accurately measure the total force on the entire roll created by tension in the web, and the readout will be precisely displayed no matter what the position of the web.

    • Rugged industrial construction
    • Positive overload stops in both compression and tension modes of operation
    • Four foil strain gauges in a full Wheatstone Bridge
    • Simple installation
    • Ability to sense actual web tension
    • Load ratings from 50 to 5,000 lbs
    • UL and CE Approved

    Measure the total force on a roll created by tension in a web

     

Tension Readouts

    DLCA Digital Load Cell Amplifier
  • DLCA Digital Load Cell Amplifier

    The new Digital Load Cell Amplifier (DLCA) is a low-cost, yet powerful and versatile DIN rail mounted digital amplifier. Even though the DLCA is compact in size it incorporates ease of use, setup with three push buttons, a four-segment display, fully programmable low pass filter for each output, tension alarm set points, quick and easy calibration, and even weightless load cell calibration.

    • Compact enclosure requires minimal space
    • Setup and calibration through 3 push buttons and digital display
    • Weightless load cell calibration
    • One push button for re-zeroing, with optional input for remote re-zeroing
    • Alarm output configurable for high tension, low tension, high and low tension, or in between high and low tension
    • Automatic load cell diagnostics/ fault indicator

     

  • DTR-65 Digital Tension Readout
  • DTR-65 Digital Tension Readout

    The DTR-65 is an easy choice when needing a tension displayed on a machine panel with the option to also output a tension reference to a drive or PLC for remotely displaying or controlling tension.

    A powerful and versatile panel-mounted digital amplifier used to display measured tension locally on a machine panel, the DTR-65 will multiply a millvolt tension signal to a usable 0 to 10 VDC and 4 to 20 mADC analog output.

    The DTR-65 is an 1/8 DIN panel mount enclosure that is IP65 protected on the face. It incorporates ease of use and setup with a keypad and a four-segment display, fully programmable low pass filter for each output, tension alarm set points, quick and easy calibration, and even weightless load cell calibration.

    • Small panel usage, 1/8 DIN enclosure (same as DTR)
    • Setup and calibration through keypad and digital display
    • Weightless load cell calibration
    • Outputs and display have fully adjustable and separate digital filtering
    • One push button for re-zeroing, with optional input for remote re-zeroing
    • Alarm output for high tension or low tension or high or low tension
    • Works with 5 and 7.5 volt excitation sensors with 1.5 to 100 mV/V signals
    • 32:1 gain adjustment
    • Automatic load cell diagnostics/fault indicator
    • Powered with 24 VDC or 100 to 240 VAC

    DTR-65 Digital Tension Readout

     

  • TSA Load Cell Amplifiers
  • TSA Load Cell Amplifiers

    When performance matters, the TSA Load Cell Amplifiers from MAGPOWR are head and shoulders above the competition, especially in the areas of drift and linear performance. These load cell amplifiers can measure tension in any moving web, wire, or strand.

    Load cell amplifiers provide power to one or two full- or half-bridge load cells, and amplify the tension measurement signal for display or feedback to any control device. They also allow maximum flexibility in the tension sensing range of any size sensor by providing a gain control range of 8:1 and a tare adjustment of 50 percent of the sensor rating.

    • Process improvement through repeatable machine settings
    • Superior drift and linearity performance for accuracy
    • Flexibility of 0-10 vdc, or 4-20 mADC output
    • Compact enclosure requires minimal space
    • Flexibility of an 8:1 sensor calibration range
    • Simplicity of DIN rail mounting
    • UL and CE Approved

    Superior accuracy when working with MAGPOWR Load Cells

     

  • Intrinsically Safe Load Cell Amplifier
  • Intrinsically Safe Load Cell Amplifier

    Safety is the key to any operation, that’s why the MAGPOWR IS-2 Intrinsically Safe Load Cell Amplifier is so valuable and important. The Model IS-2 amplifier provides intrinsically safe circuitry for UL Listed MAGPOWR load cells. It is specifically designed for safe, accurate measuring and controlling web tension in hazardous locations. When used with UL listed MAGPOWR load cells, the IS-2 is UL approved for Class I, Groups A, B, C and D; Class II, Groups E, F, G and Class III. This allows the load cells to be mounted directly in the hazardous area without air purging. The IS-2 amplifier is compatible with all MAGPOWR UL listed load cells, tension readouts and tension controls.

    • Rugged industrial enclosure
    • Compatible with all UL listed MAGPOWR load cells
    • 8:1 range adjustment. Use sensor at 1/8th of its capacity and maintain full scale indication of total web tension
    • Listed by UL for Class I, Division 1, Groups A, B, C and D; Division 1, Groups, E, F, and G and Groups III, Division 1
    • Dual meter outputs for high and low range indication

    For safe measuring of tension in hazardous locations

     

Tension Sensing Idler Rolls

    CSR Tension Sensing Roller
  • CSR Tension Sensing Roller

    The MAGPOWR CSR series is a cantilevered tension
    sensing roller that uses tension sensors embedded in the roller to provide a signal proportional to tension in any unwind, rewind or intermediate web processing application.

    When installed in place of a standard machine idler roller, the CSR tension sensing roller delivers precise web tension measurement with low temperature drift due to a full Wheatstone bridge construction on each load cell inside the roller.

    • Fast and easy installation
    • Optional readout in end of roll
    • Optional integrated RPM sensor
    • Flange and stud mount
    • Flange mount with through frame pigtail
    • Several diameters available between 80 and 152 mm (3.15 to 6 inches)
    • Roller materials in Aluminum, Steel and Stainless Steel
    • Seven load ratings
    • Lengths from 250 to 1000 mm (9.9 to 39.4 inches)
    • Force measurement in positive or negative direction
    • Optional integrated display offers display of actual tension on end of roller, weightless load cell calibration, 0 to 10 VDC output, digital filter of output and re-zero button
    • Five times overload protection in both force directions
    • Works as a stand-alone unit or with any MAGPOWR tension amplifier or tension control

    MAGPOWR CSR Tension Sensing Roller

     

  • ISR Tension Sensing Roller
  • ISR Tension Sensing Roller

    The MAGPOWR ISR series is a dead shaft tension sensing roller supported on both sides that uses tension sensors embedded in the roller to provide a signal proportional to tension in any unwind, rewind
    or intermediate web processing application.

    When installed in place of a standard dead shaft idler roller, the ISR integrated tension sensing roller delivers precise web tension measurement with low temperature drift due to full Wheatstone bridge
    construction on each load cell inside the roller.

    • Fast and easy installation
    • Several diameters available between 80 and 152 mm (3.15 to 6 inches)
    • Roller materials in Aluminum, Steel and Stainless Steel
    • Seven load ratings
    • Lengths from 235 to 3000 mm (9.3 to 118.1 inches)
    • Force measurement in positive or negative direction
    • Single bolt mounting on each end
    • Five times overload protection
    • Works with any MAGPOWR tension amplifier or tension control

    MAGPOWR ISR Tension Sensing Roller

     

Position And Diameter Sensors

    US-2 Ultrasonic Sensor
  • US-2 Ultrasonic Sensor

    Scrap is essentially waste, and waste represents reduced profits. An effective way to reduce scrap and therefore maximize profits is by increasing the accuracy and control of the web. MAGPOWR’s US-2 Ultrasonic Sensor used with VERSATEC control measures the diameter of the roll and allows your core and full roll alarms to be adjusted to give your operator proper notification before reaching the end of the roll. This fully automated ultrasonic tension control system allows you to reduce scrap by utilizing the entire roll on your web.

    • Measures the diameter of the roll
    • Allows your core and full roll alarms to be adjusted to give your operator proper notification before reaching the end of the roll
    • A critical element of a fully automated ultrasonic tension control system

    US-2 Ultrasonic Sensor

     

  • DFP2 Follower Arm Sensor Positioners
  • DFP2 Follower Arm Sensor Positioners

    The goal in dancer/follower arm applications is to utilize the dancer arm for increased accuracy in tension control, eliminating dependence on an operator and achieve automatic control of the braking torque on the unwind roll — resulting in constant web tension.

    MAGPOWR’s compact DFP-2 is perfect for use in dancer control applications with the MAGPOWR VERSATEC, and in dancer and follower arm applications with the Spyder and DFC-90. It offers the same exceptional sensing performance as the original DFP sensor, but in a lighter duty, low cost housing.

    The DFP-2 also includes a servo-type flexible coupling to allow for misalignment in shaft-to-shaft applications as well as 15 feet of shielded cabling for ease of installation. The DFP and DFP-2 use the same conductive plastic element to measure dancer and follower arm positions.

    • Rugged cast, non-magnetic housing
    • Water tight construction
    • Easy to mount

    A compact position sensor for use with VERSATEC and Spyder Tension Control

     

  • DFP Follower Arm Sensor Positioners
  • DFP Follower Arm Sensor Positioners

    The Dancer/ Follower Arm Position Sensor is designed for use in Dancer Control applications. The DFP features a rugged cast, non-magnetic housing, water tight construction and easy mounting.

    • Rugged cast, non-magnetic housing
    • Water tight construction
    • Easy to mount

     

Power Amplifiers

    PS-24 and PS-90 Power Supply
  • PS-24 and PS-90 Power Supply

    Complete control is the goal of any operation utilizing brakes and clutches. MAGPOWR’s PS-24 & PS-90 Power Supplies provide a small amount of reverse current circuitry as a standard feature to minimize the drag torque of a clutch/brake, allowing greater controllability in the lowest torque range.

    These power supply units control any size MAGPOWR clutch or brake with optimum resolution. MAGPOWR’s current-regulated power supplies are used for the control of magnetic particle clutches and brakes in unwind, rewind, or intermediate tension control applications. With selectable current ranges, these compact enclosures can be mounted inside the machine cabinet, allowing your operator to adjust torque through a remotely mounted potentiometer or with a 0 to 10 vdc control signal from MAGPOWR Open Loop and Closed Loop controllers, or any control device like a computer or PLC.

    • Provides control for a magnetic particle clutch or brake
    • Current regulated output in selectable ranges
    • Manually adjusts through a remotely mounted potentiometer or automatic controller
    • Compact enclosure requires minimal space
    • Conveniently mounts inside the Cygnus-E enclosure
    • UL and CE Approved
    • Simplicity of DIN rail mounting

    For current regulated power to Magnetic Particle Clutches and Brakes

     

  • PA-90 and PA-2 Power Amplifiers
  • PA-90 and PA-2 Power Amplifiers

    MAGPOWR’s PA-90 and PA-2 Power Amplifiers are designed to provide the extra current required for controlling magnetic particle brakes and clutches in any tension control application. For use with DIGITRAC II, EZ-Trac, or VERSATEC, the PA-90 and PA-2 can be mounted inside the control’s enclosure, and receives its control signals directly from the tension control.

    The PA-90 is used to control 90 VDC brakes and clutches only, while the PA-2 can be used to control either 24 or 90 VDC units. MAGPOWR’s power amplifiers also include reverse current circuitry as a standard feature, thus allowing greater controllability in the lowest torque range of the clutch or brake being operated.

    • Control and size magnetic particle clutch or brake
    • Output is current-regulated for better system response
    • Selectable operating current ranges for optimum controllability
    • Easily mounts inside a VERSATEC enclosure
    • Reverse current to extend torque range is standard
    • UL and CE Approved

    Designed to power magnetic particle clutches and brakes

     

Magnetic Particle Clutches And Brakes

    Global Series Brakes
  • Global Series Brakes

    Versatility and flexibility are the real benefits found in MAGPOWR’s Global Series Magnetic Particle Brakes, as they provide smooth, repeatable, controllable torque independent of speed. This makes them suitable for all kinds of power transmission and tensioning applications. Sizes are available from 5.5 to 325 lb-ft of torque.

    This line of brakes features state-of-the-art magnetic particle technology and its compact size is due to through-bores on all machined housings for ease of mounting. The M (Metric) series boasts full metric bores and keyways, as well as metric mounting hardware and setscrews to support international design requirements. The brakes are also available as 24 vdc or 90 vdc.

    Models available by Rated Torque:
    GBA: 7.5 Nm (5.5 lb-ft)
    GBB: 14 Nm (11 lb-ft)
    GBC: 35 Nm (26 lb-ft)
    GBD: 75 Nm (56 lb-ft)
    GBE: 135 Nm (100 lb-ft)
    GBF: 441 Nm (325 lb-ft)

    • Torque is proportional to current
    • Torque independent of speed
    • Smooth control of torque
    • Available in 90 and 24 volt
    • Float mounted on shaft
    • Low cost
    • UL and CE Approved
    • Torque is repeatable
    • Easy control – adjustable while running
    • Smooth starts and stops

     

  • Global Series Clutches
  • Global Series Clutches

    State-of-the-art magnetic particle technology featuring the latest materials and components, modern manufacturing techniques and a sleek design. MAGPOWR’s Global Series Clutches gives you all that and more.

    Smooth controllable torque, torque repeatability and torque independent of speed make these clutches suitable for many power transmission and tensioning applications. Long life is assured by polished seal surfaces, high temperature materials and rugged, compact construction.

    The clutch consists of two rotating members: the inner member is the rotor (output member, mounted on a rotating shaft) and the outer rotating member is the housing assembly (input member, driven by a gear, pulley or sprocket attached to the mounting rabbet provided on the side of the clutch housing). No couplings, mounting feet or other attachments are required, since the clutch becomes an integral part of your machine.

    • Polished, sealed surfaces with rugged construction for longer life
    • Easy installation
    • Compact design
    • High heat dissipation
    • UL and CE Approved

    Smooth controllable torque, torque reliability and torque independant of speed make these clutches ideal for many applications

     

  • Foot Mounted Magnetic Particle Brakes
  • Foot Mounted Magnetic Particle Brakes

    Transform your reliable, durable, foot-mounted MAGPOWR C Series Clutches into brakes with the addition of a simple locking bracket. The unit can be adapted by installing a locking bracket on an existing foot-mounted clutch, or by simply ordering a factory-converted unit.

    LB-1 / C-1
    LB-3 / C-3
    LB-10 / C-10
    LB-50 / C-50
    LB-100 / C-100

    • Long life
    • Torque proportional to current
    • Torque independent of speed
    • Constant tension
    • Smooth, accurate, repeatable torque
    • Silent operation
    • Easy to use pulleys to couple to load
    • Easy control – adjustable while running
    • Smooth starts and stops

    Easily turn Magnetic Particle Clutches into brakes

     

  • SOFSTEP® Magnetic Particle Clutches and Brakes
  • SOFSTEP® Magnetic Particle Clutches and Brakes

    Torque is the power behind tension control, but it’s useless if there’s no regulation or guidance. The original SOFSTEP brakes with MAGPOWR controls are popular throughout the industry because of the smooth controllable torque they provide for power transmission and tension applications. As the original SOFSTEP provider, MAGPOWR offers these brakes in a variety of sizes with torque ratings from 2-240 lb-in.

    Utilizing the SOFSTEP brakes and clutches, you’ll have exceptional control as torque is independent of slip speed and directly proportional to input current. These controls prevent shock and torque spikes during engagement, giving you controlled acceleration of every load.

    • No maintenance – nothing to monitor or adjust
    • Quiet operation – no slap or squeaks
    • Energy efficient
    • Compact design
    • Fast response (no mechanical parts to move, engagement happens in milliseconds)
    • Totally enclosed housing- no wear particles to contaminate environment

    Available in a variety of sizes, from 2 to 240 lb-inch

     

  • B Series Magnetic Particle Brakes
  • B Series Magnetic Particle Brakes

    B Series Shaft Mounted Magnetic Particle Brakes give operators exactly what they want: high-quality, dependable performance with no headaches. The magnetic particle brake is an inherently simple, durable device. They are easy to install, made of rugged cast iron for long life and have minimal moving parts, meaning the brakes can be mounted and start performing immediately.

    The magnetic particle brake is unique in that it acts like a torque valve, allowing any amount of torque to be passed to the load. Long life, smooth starts, and silent operation make it perfect for cycling and overload applications. The unit is offered in a variety of mounting styles in both clutch and brake configurations.

    • Torque is proportional to current
    • Torque is independent of speed
    • Easy control adjustable while running
    • Torque is repeatable
    • Self contained with shaft, bores and bearings
    • Smooth stops and starts
    • Silent operation

    Model B5, B25 and B50 brakes provide smooth operation and torque independant of speed

     

  • B-7V and B-20V Vertical Magnetic Particle Brakes
  • B-7V and B-20V Vertical Magnetic Particle Brakes

    Unlike other magnetic particle brakes, a horizontal axis is not required for shafts utilizing MAGPOWR’s B-7V & B-20V Vertical Magnetic Particle Brakes, thanks in particular to the unit’s disk-shaped rotor. Other brakes sport cylindrical designs, requiring a horizontal shaft axis. The B-7V & B-20V operate with the axis vertical, horizontal, or at any other required angle—the space between the rotor and the two sides is filled with magnetic particles, so the unit can be operated in any orientation.

    MAGPOWR’s B-7V & B-20V Vertical Magnetic Particle brakes, made of rugged cast iron for long life, are easy to install and have minimal moving parts, requiring very little installation and calibration. These brakes assist in smooth, repeatable torque that is proportional to current, and applications include tensioning of film rolls on vertical shafts, packaging machines and machine tools.

    • Torque is proportional to current
    • Torque is independent of speed
    • Easy control – adjustable while running
    • Torque is repeatable
    • Self contained with shaft, bores and bearings
    • Smooth stops and starts
    • Silent operation

    For applications where mounting to a non-horizontal shaft is required

     

  • Foot Mounted Magnetic Particle Clutch
  • Foot Mounted Magnetic Particle Clutch

    Given the scores of variables associated with any web processing operation, the last thing you want to worry about is a clutch. Thanks to the reliability and long life of the MAGPOWR C Series Magnetic Particle Clutch, an operator can mount this component, set it up and forget it. This magnetic particle clutch is cost-effective and provides silent operation, making it ideal for cycling and overload applications.

    This component features magnetic particles located inside the clutch between the O.D. of the rotor and the I.D. of the drive cylinder. With no current in the coil of this device, the particles are free to lie loosely between the rotor and the drive cylinder. When current is applied to the coil, it sets up a magnetic field in the stator. The magnetic particles line up with the magnetic field and couple the rotor to the drive cylinder. As the current is increased, the magnetic field increases and the coupling (or torque capacity) increases proportionally.

    • Silent operation
    • Smooth, accurate, repeatable torque
    • Options for air or water cooling
    • Cast iron materials for long life
    • Easy to mount
    • Cost effective
    • UL and CE Approved

    A typical installation of Magnetic Particle Clutches

     

  • Cooling Options for MAGPOWR Clutches and Brakes
  • Cooling Options for MAGPOWR Clutches and Brakes

    Used under slip conditions, MAGPOWR Clutches and Brakes generate significant heat that must be dissipated. Often, that heat is dispersed via that model’s convection cooling ability. If the application exceeds the dissipation capacity of a convection cooled model, additional heat dissipation capacity can be achieved through the addition of MAGPOWR’s forced air or water cooled options. The addition of these accessories can increase the heat dissipation capacity by 300-500 percent.

    FORCED AIR COOLED: The air hood and blower assembly is a pre-assembled shroud that forces air from the blower through the clutch or brake. Forced air-cooling is particularly useful on applications having a low RPM unit. Factory assembled units with this option are designated by the letter “A” after the model number.

    WATER COOLED: In these units water is forced into the hollow rotor through a tube in the shaft and is returned through the shaft to the special water fitting or coupling. Water-cooled clutches and brakes are designated by the letter “W” after the model number. Water fittings must be ordered separately.

    FORCED AIR & WATER COOLED: The Forced Air and Water Cooled combo on a MAGPOWR unit gives maximum heat dissipation capacity. Factory assembled units with both options are designated by the letters “WA.”

    OVERSPEED CONTROL: An additional option to these cooling methods on rewinds is to use the ‘inverse diameter’ option available with some of our open loop and closed loop controllers. The controllers limit overspeed and thus heat as a rewind roll grows in diameter and the rpm slows.

High Efficiency Brake

    HEB250
  • HEB250

    The MAGPOWR HEB250 pneumatic brake packs many powerful features into a compact design. Ideal for the demands of general converting and corrugating operations, the HEB produces higher torque at cooler brake pad temperatures. These cooler temperatures along with a thicker brake pad will ensure longer pad life to minimize downtime.

    The HEB is engineered for rugged environments, utilizing a single, ventilated cast iron rotor with a bi-directional flute design which allows for efficient cooling when used in either direction of rotation, a through bore and keyway design for easy mounting of the rotor to the brake shaft and an integrated set of caliper mounting brackets that can be mounted directly to the machine frame. These caliper mounting brackets are also an integral part of the safety guarding along with the caliper bodies to reduce the overall size of the brake.

    Web tension is accurately controlled by adjusting air pressure to the calipers, pushing brake pads against each side of the rotor to produce consistent brake torque.

    • Small compact size
    • Through bores and keyways
    • Inch and metric bores
    • Optional mounting adapter
    • High torque output
    • High heat dissipation
    • Longer pad life
    • Bi-directional cooling
    • Optional integrated proximity sensor

     

Perma-Tork

    Permanent Magnet Clutches and Brakes
  • Permanent Magnet Clutches and Brakes

    Smooth, precise control is the objective of all clutches and brakes, but few achieve one—never mind both—of these goals. MAGPOWR’s innovative Perma-Tork® permanent magnet clutches are capable of producing highly accurate, dependable torque, without the need of an external power source. The clutches (available in hysteresis or magnetic particle) use high energy, multi-pole magnets to establish lines of magnetic force that retard the motion of the center rotating disc, delivering smooth, precise control.

    Designed for long-lasting, reliable performance, Perma-Tork clutches are commonly used in light torque control applications, including tensioning, torque limiting, magnetic coupling and testing.

    • Breakthrough permanent magnet technology requires no external control or power source
    • Unique design provides torque constant or proportional with respect to speed
    • Fast, precise torque adjustment. Durable, long-lasting operation – no maintenance required
    • Versatile mounting options ensure quick and easy installation
    • Compact design requires minimal space

    The original Perma-Tork brake from MAGPOWR

     

Meters And Accessories

    Digital Tension Meter
  • Digital Tension Meter

    A low-cost way to monitor tension output, the Digital Tension Meter (DTM) is perfect for applications where access to tension control parameters is not required. Operators can mount a control away from the web to get feedback on current web tension via a backlit display and illuminated digits. The DTM is encased in high-impact plastic to withstand demanding conditions. A sealed front panel meets industry-standard NEMA 4X/IP65 specifications for wash-down and dusty environments.
    This meter can be used with any tension sensor amplifier by reading the 0 to 1 mA meter output reference.

    • Easy to read LCD
    • Built-in scaling
    • Auto zeroing circuit
    • Compact enclosure fits DIN standard cut-out
    • NEMA 4X/IP65 sealed front panel bezel
    • Wire connections made via screw clamp type terminals

     

  • TR-5
  • TR-5

    The MAGPOWR TR-5 Tension Readout is a device for measuring tension in a moving web, strand, wire or narrow tape. It uses either one or two MAGPOWR load cells and interconnection cables.

    This system can be used on any non-driven idler roll or at any position where the wrap angle of the web or strand does not change. Each load cell contains four foil type strain gages bonded to a sensing beam. These gages convert the load on the roll or sheave to an electrical signal. Within the TR-5, the signal from the load cells is amplified and displayed on the tension meter.

    The amplifier of the TR-5 has low drift and high linearity, with a gain control range of 8:1 and tare adjustment of 50%. An auxiliary 0 to 10 VDC, or 4 to 20 mADC output is provided for interfacing to other products or systems.

    • Precision tension meter for direct tension readout
    • 8:1 calibration range
    • Tare adjustment of 50% load cell rating
    • Overall system accuracy better than 1%
    • Auxilary 0 to 10 VDC or 4 to 20 mADC output
    • Operates with either one or two load cells
    • Easy to install and calibrate
    • Improved productivity by eliminating operator dependency
    • Improved quality through reproducible correct machine settings
    • Switch selectable 115/230 VAC input

     

Current To Pressure Transducers

    IPT-E
  • IPT-E

    MAGPOWR’s IPT-E Current to Pressure Transducer provides two benefits right out of the box: its single manifold design facilitates its small size, and the unit requires absolutely no calibration, so it’s ready-to-use immediately. Versatile and easy to use, the IPT-E provides superior response, accuracy, and flow characteristics, which are critical in precise tensioning applications. The unit operates on 115/230 VAC, normal dry shop air, and accepts a 4-20 ma control input signal.

    • Superior response for control applications
    • Compact surface mount design
    • Ready to use, no calibration required
    • Operates any pneumatic clutch or brake, regardless of make or size
    • Accepts 4-20 mADC control input signal
    • Accurate and repeatable
    • IP65 protection against dirt and liquids
    • Optional pressure gauge and air line filter kits are available
    • UL and CE Approved

     

    A compact pressure controller designed to operate pneumatic brakes and clutches in precise tension applications

     

  • IPT
  • IPT

    Space is always at a premium inside working machinery. MAGPOWR knows this well, and therefore constructed its IPT Current or Voltage to Pressure Transducer as a single-manifold design to surface mount inside a machine enclosure. It is designed to be mounted in any orientation with no affect on performance and offers multiple mounting options. The IPT can be mounted on standoffs through four provided mounting holes, or on a DIN 35 rail using the provided mounting clips, or in a customer supplied DIN 35 Modular Circuit Housing.

    Perfect for control applications, the IPT is ready to use right out of the box, requiring no calibration and providing superior response, accuracy, and flow characteristics. Versatile and easy to use, the IPT is an ultra-compact PC board level pressure controller that operates on 115/230 VAC and filtered dry shop air, and can accept either a current or voltage control input signal.

    • Superior response for control applications
    • Compact surface mount design
    • Ready to use, no calibration needed
    • Operates any pneumatic clutch or brake, regardless of make or size
    • Accepts current or voltage control input signal
    • Accurate and repeatable
    • Multiple mounting options

    A compact PC board level pressure controller designed to be mounted inside a machine closure.

     

  • IP-80
  • IP-80

    Versatility, accuracy, durability and ease of use. These are the things you look for in a current-to-pressure transducer, and that’s exactly what you get in the MAGPOWR IP-80. Built into this compact, vibration- and shock-resistant industrial duty unit is an accurate, easy-to-read pressure gauge that monitors output pressure. The flexible IP-80 operates on normal filtered shop air and allows a wide variation in supply pressure, offers high flow and exhaust characteristics to insure rapid response of any clutch or brake and can be placed almost anywhere. The IP-80 includes the transducer, 20-psi reference regulator, dual reference air filters with automatic drains, air regulator and volume pressure booster.

    • Operates with any pneumatic clutch or brake regardless of make or size
    • Compact size
    • Complete and ready to install
    • Pressure gauge for monitoring output pressure
    • Dual air filters with automatic drain
    • High flow and exhaust characteristics
    • Rugged vibration and shock resistant industrial duty unit
    • Shock & Vibration Effect on Output Pressure: Negligible at 3 G between 5 to 200 Hz

    Complete, compact, and ready to install Current to Pressure Transducer assembly.

     

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