MHR Enrange MHR Radio Controller August 2014 Part Number: 195-50488-0100 R5 © 2014 Magnetek Material Handling
Your New Radio Receiver Thank you for your purchase of Magnetek’s EnrangeTM MHR Radio Controller. Magnetek has set a whole new standard in wireless control performance, dependability, and value with this unique new line of Mobile Hydraulic Controllers. If your product ever needs modification or service, please contact one of our representatives at the following locations: U.S. Service Information For questions regarding service or technical information contact: 1.866.MAG.SERV (1.866.624.7378).
TABLE OF CONTENTS 1.0 CRITICAL INSTALLATION CONSIDERATIONS..................................................................... 5 1.1 GENERAL .............................................................................................................................. 5 1.2 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED EQUIPMENT ................ 6 1.3 SAFETY INFORMATION & RECOMMENDED TRAINING FOR OPERATORS .................. 6 1.4 PRE-OPERATION TEST ........................................................
PRODUCT MANUAL SAFETY INFORMATION Magnetek, Inc. (Magnetek) offers a broad range of radio remote control products, control products and adjustable frequency drives, and industrial braking systems for overhead material handling applications. This manual has been prepared by Magnetek to provide information and recommendations for the installation, use, operation and service of Magnetek’s material handling products and systems (Magnetek Products).
WARNINGS and CAUTIONS Throughout this document WARNING and CAUTION statements have been deliberately placed to highlight items critical to the protection of personnel and equipment. WARNING – A warning highlights an essential operating or maintenance procedure, practice, etc. which if not strictly observed, could result in injury or death of personnel, or long term physical hazards.
1.0 CRITICAL INSTALLATION CONSIDERATIONS WARNING ONLY QUALIFIED INSTALLERS SHOULD INSTALL THIS RADIO CONTROL EQUIPMENT. THIS MANUAL SHOULD BE CONSULTED TO MINIMIZE POTENTIAL HAZARDS WITH THE EQUIPMENT INTERFACED. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
1.2 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED EQUIPMENT Only properly trained persons designated by management should be permitted to operate radio controlled equipment. Radio controlled cranes, hoists, lifting devices and other material handling equipment should not be operated by any person who cannot read or understand signs, notices and operating instructions that pertain to the equipment.
Operate the crane, hoist or lifting device unless all persons, including the operator, are and remain clear of the supported load and any potential pinch points Operate a crane, hoist or lifting device when the device is not centered over the load Operate a crane, hoist or lifting device if the chain or wire rope is not seated properly in the sprockets, drum or sheave Operate any damaged or malfunctioning crane, hoist, lifting device or other material handling equipment Change any setting
WARNING PRIOR TO OPERATING EQUIPMENT WITH THIS RADIO CONTROL SYSTEM, THE EQUIPMENT BEING CONTROLLED SHOULD BE INSPECTED FOR ANY DAMAGE. DO NOT OPERATE DAMAGED EQUIPMENT. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT. WARNING THIS RADIO CONTROL EQUIPMENT CONTAINS RADIO TRANSMITTERS AND RECEIVERS THAT RADIATE RADIO FREQUENCY ELECTROMAGNETIC WAVES. THIS EQUIPMENT HAS BEEN TESTED AND IS IN COMPLIANCE WITH STANDARDS EN 301 489-1 AND EN 301 489-3.
WARNING THIS RADIO CONTROLLER IS EQUIPPED WITH AN INFRARED TRANSMITTER. THE OPERATOR SHOULD BE AWARE OF THESE RISKS AND AVOID LOOKING DIRECTLY INTO THE INFRARED TRANSMITTER DURING OPERATION. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN INJURY. WARNING SOME EQUIPMENT THAT CAN BE INTERFACED WITH THIS RADIO CONTROLLER WILL HAVE MANUAL CONTROLS ALONG WITH THE RADIO CONTROLS. THE OPERATOR SHOULD BE PROPERLY QUALIFIED TO OPERATE THE EQUIPMENT WITH MANUAL CONTROLS.
WARNING SOME EQUIPMENT THAT CAN BE INTERFACED WITH THIS RADIO CONTROLLER WILL HAVE ENGINE EXHAUST FUME HAZARDS. THE OPERATOR SHOULD BE AWARE OF THESE RISKS AND SHOULD NOT OPERATE THE RADIO CONTROLLER IN AN ENVIRONMENT WHERE THERE IS AN INSUFFICIENT SUPPLY OF FRESH AIR. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT. WARNING THE RADIO CONTROLLED EQUIPMENT OPERATOR IS RESPONSIBLE FOR THE SAFE HANDLING OF ALL LOADS IN ALL ENVIRONMENTAL CONDITIONS.
2.0 MHR RECEIVER INSTALLATION WARNING PRIOR TO INSTALLATION AND OPERATION OF THIS EQUIPMENT, MAGNETEK SHOULD BE CONSULTED TO ASSESS THE OVERALL RISKS IN OPERATING THE EQUIPMENT INTERFACED. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT. WARNING SOME EQUIPMENT THAT CAN BE INTERFACED WITH THIS RADIO CONTROLLER WILL HAVE HIGH LEVELS OF ACOUSTIC NOISE.
WARNING UNSTABLE LOADS OR EQUIPMENT CAN LEAD TO UNSAFE CONDITIONS IN SOME EQUIPMENT. THE INSTALLER SHOULD BE AWARE OF THESE RISKS AND INSTALL THE RADIO CONTROLLER IN A MANNER THAT MINIMIZES UNSTABLE EQUIPMENT OR LOAD CONDITIONS. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT. WARNING SOME EQUIPMENT THAT CAN BE INTERFACED WITH THIS RADIO CONTROLLER WILL HAVE MANUAL CONTROLS INSTALLED.
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Figure 04: MHR with Con1 and Con2 connectors Figure 05: MHR Side View 2.3 INSTALLATION 1. 2. 3. 4. 5. 6. 7. Determine the location of your antenna from Figures 01-03 (antenna is designated with red arrow). Be sure to mount receiver antenna in direct line-of-sight of operator and free from all obstructions. Do not mount receiver near high levels of electric noise, such as an unshielded variable frequency drive, as it may cause minor interference. Allow adequate room for mounting the receiver.
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+Vbattery (CON1 D3 and CON2 K1, K2, K3) The MHR is designed to work in any 12-24VDC nominal (9-36VDC max) powered equipment. The +Vbattery pins should be connected to the positive terminal of the machine power supply through an approved Emergency Stop device. Additionally, MHR +Vbattery pins should be protected by a 30A fast blow fuse. All +Vbattery pins must be connected.
Analog/Digital Inputs (CON1, E1, E2, E3, F1, F2, F3) These six pins can be configured as either analog or digital inputs. The input source used on these pins must be able to drive 40K Ohm input impedance. Analog voltage range is from 0 to 12V. The analog input utilizes a 10bit analog to digital converter. The digital voltage range is as follows: inputs less that 2V are a digital 0; inputs greater than 3V are a digital 1; the output remains unchanged for inputs between 2 and 3V.
Figure 08: MHR driving Current Compensated or PWM load using Return Pin and internal diodes NOTE: This is a simplified schematic. Figure 09: MHR PWM or Digital ON/OFF load using external ground and external diodes NOTE: This is a simplified schematic. PWM and digital outputs are not required to make use of the return pin. However, if the return pin is utilized, use of an external diode is not needed for inductive loads.
In total, the MHR can be configured for: Up to 8 bi-directional Current Compensated outputs (pairs are interlocked to prevent simultaneous motion) Up to 8 bi-directional PWM outputs (pairs are interlocked to prevent simultaneous motion) Up to 16 single directional digital ON/OFF outputs Up to 16 single directional digital ON/OFF inputs NOTE: The total number of IOs on the unit is limited by its configuration, i.e.
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3.0 CONFIGURING THE MHR The Setup Mode can be used to edit configuration settings so that the MHR can be used in many different scenarios. NOTE: No parameter changes will take effect until the user has selected ‘Save and Exit’ from the Setup Mode. 3.1 ENTERING SETUP MODE To enter the setup mode, hold the UP and BACK buttons at the same time. If the password feature is enabled on the MHR, you will be prompted for a password prior to entering setup mode.
For example, entering the factory default password in the password entry screen is as follows: Press , Press Press , Press , , , and the screen should now read 3500. to move the highlight over to the next digit to the right. , Press Press and the screen should read 3000 to move the highlight over to the next digit to the right. Press Press , , , , , , , and the screen should now read 3570. to move the highlight over to the next digit to the right.
3.2 SETUP MODE MENU To cycle through the list use the button. The and buttons. To enter a submenu, use the button will take the user back to the Setup Mode menu Figure 11: Setup Mode Main Menu Setup Mode Menu: This screen allows the user to select which Configuration Menu to enter. A brief description of each menu is also listed.
Example of how to navigate the setup menu to the Unit status screen: Once in the main menu for the setup mode, Press Press , , and the menu selection should read “Unit Status” to enter the “Unit Status” sub-menu. There are no user selectable options in the unit status menu screen. When finished, press to return to the main setup mode menu.
• Access Code The access code acts as the receiver address. The receiver will only listen to transmitters with the same address. NOTE: The transmitter must be set with the same access code as the receiver to properly communicate with each other. WARNING THE ACCESS CODES IN THE RECEIVER ARE UNIQUE AND FACTORY PRESET. DO NOT CHANGE THESE ACCESS CODES UNLESS YOU ARE REPLACING AN EXISTING RECEIVER AND ITS ACCESS CODE.
WARNING ALWAYS REMEMBER TO STORE THE PASSWORD IN A SECURE LOCATION FOR ACCESS IF THE PASSWORD IS LOST OR FORGOTTEN. ONCE THE RECEIVER IS PROGRAMMED WITH A PASSWORD, THERE IS NO WAY TO DEFEAT THE PASSWORD WITHOUT USING THE RCP SOFTWARE TO EITHER READ THE PASSWORD OR REPROGRAM A NEW PASSWORD. • Pass Enable (Enable or disable the password) The password is used to restrict access to the configuration menu on the MHR. Having an active password prevents accidental changes to the receiver.
through each digit. Use the and buttons to change the values of the digit selected. After the last digit is entered on the far right side of the date screen, press to return to the setup menu. • Time This menu option allows the operator to adjust the time that is stored on the MHR. The time can be adjusted by using the digit. Use the and and buttons to cycle through each buttons to change the values of the digit selected.
To adjust the PWM frequency setting, select the PWM Frequency option and use the and buttons to cycle through each digit. Use the and buttons to change the values of the digit selected. After the last digit is entered on the far right side of the PWM Frequency screen, press • to return to the setup menu. Output # (There will be one for each output available on the unit) Use the and number and press the selected.
3.4.1 INDIVIDUAL OUTPUT CONFIGURATION Figure 14: Individual Output Configurations Individual Output Configuration: Once an individual output is selected, the following parameters may be changed: • Config Type – This menu option allows the user to set the MHR outputs up for the application in which it is being used.
The following setting options are used to configure the selected output for the application being used and can be accessed through the individual output menus for each output number. NOTE: The following setting options have no effect when the output Config Type is set to Digital Output or Digital Input. Minimum Current (Only used for Current Comp) • Sets the minimum output current for the selected output number. • The range is 100 to 3000mA.
3.5 CAN CONFIGURATION Figure 15: CAN Configuration CAN Configuration: This screen allows the user to make changes to the CAN 1 and CAN 2 settings. The operator can choose between adjusting the settings for CAN 1 and/or CAN 2. The two CAN networks are independent from each other. Use the and the buttons to change between the settings for CAN 1 and CAN 2 and press button to enter the setting options selected. Press the button to return to the CAN setting option menu.
• • • CAN 1 Source Addr - This is the address that the MHR will use as the source address when transmitting messages on the CAN 1 bus network. • 0 through 255 CAN 1 Identifier Bit - This option allows the operator to select between an 11 bit or 29 bits identifier for the CAN 1 network • 11 bits • 29 bits CAN 1 Term Resistor - This option allows the user to enable/disable the internal terminating resistor.
Serial Number Project ID TX ID Access Code Hours Channel Temp (°C) Time & Date Figure 16: Unit Status Field Serial number Project ID Access Code RF Channel Time and Date TX ID Hours Temperature Description Every unit has a unique serial number associated with it. Magnetek assigned project ID. Unit access code that the transmitter needs to know in order to communicate with the receiver. This is typically the same as the serial number, but can be changed.
4.0 NORMAL OPERATION WARNING PRIOR TO OPERATING EQUIPMENT WITH THIS RADIO CONTROL SYSTEM, THE EQUIPMENT BEING CONTROLLED SHOULD BE INSPECTED FOR ANY DAMAGE. DO NOT OPERATE DAMAGED EQUIPMENT. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT. When starting up the MHR in the normal operation mode, the MHR will cycle through a few startup screens before going to the normal operation screen. 4.
RX Access Code and RX Channel: This second screen displays what the RX Access Code and Channel the receiver is set to. The Access Code indicates the code needed by the Transmitter to control the Receiver. If the Transmitter and Receiver Access Code do not match, no communication will occur. NOTE: During initialization of the MHR, both the PWR/COMM and STATUS/ERR LEDs will briefly illuminate. This is a normal function of the initialization process for the MHR. 4.
Field Description of Fault Fault Number Input Values Proportional Output Commands Latched Output Commands CAN-bus Commands RF Status Indicator Transmitter Battery Indicator Receiver watch dog Description In this example, Output 11 has an Overcurrent Error due to a faulty solenoid. See Section 4.3 for information regarding the normal operating status indications. Each fault has a number and letter indicating an “S” System or “A” User alarm, which is useful in troubleshooting and installation.
4.4 LED STATUS INDICATION The MHR has two LEDs for indicating the MHR status at a glance during normal operation. The left LED indicates the MHR’s status while the right LED indicates power/communication. STATUS/ERR Indication LED PWR/COMM Indication LED 4.4.1 STATUS/ERR LED (left LED on MHR faceplate) Solid Green = Okay, no errors present Solid Red = Error Check the main screen for the error code and refer to Section 7.0 for troubleshooting and alarm code tables. 4.4.
5.0 OPTIONAL PROGRAMMING WITH RCP Using the optional RCP software makes programming of the MHR easier and allows for settings to be saved for future reference. WARNING THE USE OF RCP (RADIO CONTROL PROGRAMMER) IS INTENDED FOR USE BY AUTHORIZED PERSONS ONLY. CHANGES TO ANY RADIO DATA VALUE MAY LEAD TO UNEXPECTED, UNDESIRABLE, OR UNSAFE OPERATION OF EQUIPMENT AND FURTHERMORE MAY LEAD TO EQUIPMENT DAMAGE, PERSONAL INJURY, OR EVEN DEATH.
WARNING THE ACCESS CODES IN THE RECEIVER ARE UNIQUE AND FACTORY PRESET. DO NOT CHANGE THESE ACCESS CODES UNLESS YOU ARE REPLACING AN EXISTING RECEIVER AND ITS ACCESS CODE. CHANGING THIS CODE COULD MAKE IT COMMON WITH ANOTHER RECEIVER ACCESS CODE, WHICH COULD MOVE OTHER EQUIPMENT. NO TWO SYSTEMS IN ANY LOCATION SHOULD EVER HAVE THE SAME ACCESS CODES INDEPENDENT OF THE FREQUENCY. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH, AND DAMAGE TO EQUIPMENT. 5.
WARNING MHR RECEIVERS UTILIZING A DIFFERENT POWER SOURCE FROM THE COMPUTER SYSTEM BEING CONNECTED TO IT CAN HAVE A DIFFERENT GROUND POTENTIAL FROM THE COMPUTER SYSTEM. DIFFERENT GROUND POTENTIALS WILL DAMAGE EITHER THE COMPUTER SYSTEM OR THE MHR RECEIVER. AN ISOLATED USB HUB MUST BE UTILIZED TO PREVENT DAMAGE TO THE MHR, THE COMPUTER SYSTEM BEING CONNECTED TO THE MHR, OR BOTH. 5.
6.0 CHANNEL AND FREQUENCY DESIGNATIONS BY COUNT Table 400 MHz Part 15 Channel Frequency 01) 433.000 MHz 02) 433.050 MHz 03) 433.100 MHz 04) 433.150 MHz 05) 433.200 MHz 06) 433.250 MHz 07) 433.300 MHz 08) 433.350 MHz 09) 433.400 MHz 10) 433.450 MHz 11) 433.500 MHz 12) 433.550 MHz 13) 433.600 MHz 14) 433.650 MHz 15) 433.700 MHz 16) 433.750 MHz 17) 433.800 MHz 18) 433.850 MHz 19) 433.900 MHz 20) 433.950 MHz 21) 434.000 MHz 22) 434.050 MHz 23) 434.100 MHz 24) 434.150 MHz 25) 434.200 MHz 26) 434.250 MHz 27) 434.
Compliance Statement (Part 15.19) This device complies with Part 15 of FCC rules. Operation is subject to the following two conditions: 1. This device may not cause harmful interference, and 2. This device must accept any interference received, including interference that may cause undesired operation. This portable transmitter with its antenna complies with FCC’s RF exposure limits for general population/uncontrolled exposure. Warning (Part 15.
7.0 TROUBLESHOOTING 7.1 TROUBLESHOOTING TABLE Problems Receiver will not turn on Possible Reasons Suggestions Supplied voltage is out of the Ensure the voltage is with 12-24VDC acceptable range nominal (9-36VDC max). Internal fuse has blown Incorrect system RF channel Contact the factory. Make sure the receiver and transmitter unit are both set to the same RF channel. Incorrect system access Make sure the receiver and transmitter both code have the same access code.
CAN messages transmitted by the receiver are not being received Incorrect source address Make sure that the source address of the receiver is set correctly. The termination resistor is Ensure the termination resistor is set incorrectly appropriately set. Incorrect baud rate Ensure the correct baud rate is set by all devices on the bus. The display will only operate from -20°C to Display is not functioning Temperature is out of the 70°C.
7.2 ALARM TABLE Alarm Number Alarm Text Cause of alarm 0 S0. ESTOP ACTIVE E-stop activated from the transmitter Effect of alarm 1. Both E-stop outputs active 2. All outputs shut off as defined by the project 1. CAN message not received and processed 2. Depending on how the CAN messages are used, outputs may be shut off as defined by the project Recovery Action Disable condition that activated e-stop and press start Determine why the message(s) is (are) not being received.
Alarm Number Alarm Text 18 S18. OUT 3 OC ERR 19 S19. OUT 4 OC ERR 20 S20. OUT 5 OC ERR 21 S21. OUT 6 OC ERR 22 S22. OUT 7 OC ERR 23 S23. OUT 8 OC ERR 24 S24. OUT 9 OC ERR Cause of alarm When the output was activated, a current of over 3.5A was being drawn by the output. The output was shut off to prevent damage to the hardware. When the output was activated, a current of over 3.5A was being drawn by the output. The output was shut off to prevent damage to the hardware.
Alarm Number Alarm Text 25 S25. OUT 10 OC ERR 26 S26. OUT 11 OC ERR 27 S27. OUT 12 OC ERR 28 S28. OUT 13 OC ERR 29 S29. OUT 14 OC ERR 30 S30. OUT 15 OC ERR 31 S31. OUT 16 OC ERR Cause of alarm When the output was activated, a current of over 3.5A was being drawn by the output. The output was shut off to prevent damage to the hardware. When the output was activated, a current of over 3.5A was being drawn by the output. The output was shut off to prevent damage to the hardware.
Alarm Number Alarm Text 32 S32. OUT 1 +VB SHORT 33 S33. OUT 2 +VB SHORT 34 S34. OUT 3 +VB SHORT 35 S35. OUT 4 +VB SHORT 36 S36. OUT 5 +VB SHORT 37 S37. OUT 6 +VB SHORT Cause of alarm When the output is supposed to be at VBat, a voltage of 2V or greater was seen on the output. The output was shut off to prevent damage to the hardware. When the output is supposed to be at VBat, a voltage of 2V or greater was seen on the output. The output was shut off to prevent damage to the hardware.
Alarm Number Alarm Text 38 S38. OUT 7 +VB SHORT 39 S39. OUT 8 +VB SHORT 40 S40. OUT 9 +VB SHORT 41 S41. OUT 10 +VB SHORT 42 S42. OUT 11 +VB SHORT 43 S43. OUT 12 +VB SHORT Cause of alarm When the output is supposed to be at VBat, a voltage of 2V or greater was seen on the output. The output was shut off to prevent damage to the hardware. When the output is supposed to be at VBat, a voltage of 2V or greater was seen on the output. The output was shut off to prevent damage to the hardware.
Alarm Number Alarm Text 44 S44. OUT 13 +VB SHORT 45 S45. OUT 14 +VB SHORT 46 S46. OUT 15 +VB SHORT 47 S47. OUT 16 +VB SHORT 48 S48. OUT 1 -VB SHORT 49 S49. OUT 2 -VB SHORT Cause of alarm When the output is supposed to be at VBat, a voltage of 2V or greater was seen on the output. The output was shut off to prevent damage to the hardware. When the output is supposed to be at VBat, a voltage of 2V or greater was seen on the output. The output was shut off to prevent damage to the hardware.
Alarm Number Alarm Text 50 S50. OUT 3 -VB SHORT 51 S51. OUT 4 -VB SHORT 52 S52. OUT 5 -VB SHORT 53 S53. OUT 6 -VB SHORT 54 S54. OUT 7 -VB SHORT 55 S55. OUT 8 -VB SHORT Cause of alarm When the output is supposed to be at +VBat, a voltage of 2V or less was seen on the output. The output was shut off to prevent damage to the hardware. When the output is supposed to be at +VBat, a voltage of 2V or less was seen on the output. The output was shut off to prevent damage to the hardware.
Alarm Number Alarm Text 56 S56. OUT 9 -VB SHORT 57 S57. OUT 10 -VB SHORT 58 S58. OUT 11 -VB SHORT 59 S59. OUT 12 -VB SHORT 60 S60. OUT 13 -VB SHORT 61 S61. OUT 14 -VB SHORT Cause of alarm When the output is supposed to be at +VBat, a voltage of 2V or less was seen on the output. The output was shut off to prevent damage to the hardware. When the output is supposed to be at +VBat, a voltage of 2V or less was seen on the output. The output was shut off to prevent damage to the hardware.
Alarm Number Alarm Text 62 S62. OUT 15 -VB SHORT 63 S63. OUT 16 -VB SHORT Cause of alarm When the output is supposed to be at +VBat, a voltage of 2V or less was seen on the output. The output was shut off to prevent damage to the hardware. When the output is supposed to be at +VBat, a voltage of 2V or less was seen on the output. The output was shut off to prevent damage to the hardware.
7.3 ASSEMBLY AND REPLACEMENT PARTS If your receiver ever needs repair, we always recommend that you have Magnetek perform the repair. If you need to refer to a parts list, refer to your receiver’s drawing that was included in the shipment of your receiver. Please contact Magnetek’s service department at 1.800.MAG.SERV for information regarding parts and service.
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