Flex PRO / Flex M Pre-Engineered Radio Control System Part Number: 191-00195-1200 April 2012 © 2012 Magnetek Material Handling
TABLE OF CONTENTS 1. INTRODUCTION....................................................................................................................................... 6 2. RADIO CONTROLLED SAFETY ............................................................................................................. 7 2.1. WARNINGS AND CAUTIONS .............................................................................................................. 7 2.2. CRITICAL INSTALLATION CONSIDERATIONS ....................
10. RECEIVER CHANNEL CONFIGURATION SETTINGS (BANK 2 ON RF/CPU MODULE) .............. 32 10.1. CHANNEL DIP SWITCH SETTINGS FOR 433MHZ PART 15, VERSION 2 RF/CPU MODULE (25-02074-816E) ................................................................................................................................................ 33 10.2. FLEX M 24 AND 32 RELAY PRE-ENGINEERED WIRING ............................................................. 34 10.3. FCC STATEMENTS .............................................
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 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).
Your New Flex PRO/Flex M Radio Control System ® Thank you for your purchase of Magnetek’s Enrange brand Flex PRO/Flex M Radio Remote Equipment Control. Magnetek has set a whole new standard in radio-remote performance, dependability, and value with this line of modular receivers. 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.
1. INTRODUCTION The Flex radio remote control systems are designed for control of industrial equipment and machinery such as overhead traveling cranes, jib cranes, gantry cranes, tower cranes, electric hoists, winches, monorails, conveyor belts, mining equipment and other material handling equipment where wireless control is preferred.
2. RADIO CONTROLLED SAFETY 2.1. 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.
2.2. CRITICAL INSTALLATION CONSIDERATIONS WARNING PRIOR TO INSTALLATION AND OPERATION OF THIS EQUIPMENT, READ AND DEVELOP AN UNDERSTANDING OF THE CONTENTS OF THIS MANUAL AND THE OPERATION MANUAL OF THE EQUIPMENT OR DEVICE TO WHICH THIS EQUIPMENT WILL BE INTERFACED. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
2.5. SAFETY INFORMATION AND RECOMMENDED TRAINING FOR RADIO CONTROLLED EQUIPMENT OPERATORS Anyone being trained to operate radio controlled equipment should possess as a minimum the following knowledge and skills before using the radio controlled equipment.
• 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 settings or controls without authorization and proper training • remove or obscure any warning or safety labels or tags • leave any load unattended while lifted •
2.8. BATTERIES WARNING KNOW AND FOLLOW PROPER BATTERY HANDING, CHARING, AND DISPOSAL PROCEDURES. IMPROPER BATTERY PROCEDURES CAN CAUSE BATTERIES TO EXPLODE OR DO OTHER SERIOUS DAMAGE. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT. 2.9. BATTERY HANDLING Use only batteries approved by Magnetek for the specific product. Do not dispose of a battery pack in fire; it may explode. Do not attempt to open the battery pack. Do not short circuit the battery.
2.12. SPECIFIC SYSTEM WARNINGS Below are some specific operating safety tips that should be strictly followed when operating a Flex Pro system: 1. Check the Status LED on the transmitter for any signs of low battery power (refer to Section 11.1). 2. Check the Status LED on the transmitter for any signs of irregularities (refer to Section 11.1). 3. Make sure the system is not set to the same channel as any other Flex systems in use within a distance of 300 meters (900 feet). 4.
3. GENERAL TRANSMITTER INFORMATION 3.1. EXTERNAL ILLUSTRATION (PRO 12 CONFIGURATION) Figure 1 E. Emergency Stop Button S. Removable Power Key Switch 1. Push Button #1 2. Push Button #2 3. Push Button #3 4. Push Button #4 5. Push Button #5 Figure 2 6. Push Button #6 7. Push Button #7 8. Push Button #8 9. Push Button #9 10. Push Button #10 11. Push Button #11 12. Push Button #12 SC. Strap Ring SN. System Information RN. System Channel MN. Machine Number FC. FCC Information NOTES: 1.
3.2. INTERNAL ILLUSTRATION (PRO 12 CONFIGURATION) Figure 3 1. 2. 3. 4. 5. Encoder Board Aerial Antenna Transmitting Module Status LED Display Function LED Displays Figure 4 6. 7. 8.
3.3. TYPES OF BUTTONS The buttons used on the Flex Pro are fully proportional, stepless push buttons with an output that varies 0-100% (based on how far the button is depressed). Please consult the factory for more information. 3.4. ADJUSTABLE SPEED CONTROL The proportional buttons normally operate on a scale from 0-100%, but can also be scaled down to operate linearly from 0-25% over the full motion of the button. This gives the user more control over lower speeds.
4. DIP SWITCH SETTINGS 4.1. SYSTEM CHANNEL SETTINGS Set the transmitter channel by adjusting the channel dip-switch located on the backside of the transmitter encoder board (refer to Figure 7 below). Only the first five (5) positions of the dip-switch are used for channel programming (refer to Figure 8 below). The system channels table (Section 5) illustrates which dip-switch setting corresponds to which channel.
4.2. INACTIVITY TIME OUT TIMER Bits 6 and 7 on the dip-switch allows the user to define a time after which, if no buttons on the transmitter are pressed, the Flex Pro will send an OFF command to the receiver and power down. To restart, the user must turn the On/Off/Start switch to the Off position, then back to On again to resume operation. Time Out Dip-switch Setting 5 minutes 01 10 minutes 10 15 minutes 11 Never shut off 00 Figure 9 4.3.
5. SYSTEM CHANNEL TABLE Channel Frequency Dip-switch Setting Channel Frequency Dip-switch Setting 01 433.000MHZ 00000 17 433.800MHZ 10000 02 433.050MHZ 00001 18 433.850MHZ 10001 03 433.100MHZ 00010 19 433.900MHZ 10010 04 433.150MHZ 00011 20 433.950MHZ 10011 05 433.200MHZ 00100 21 434.000MHZ 10100 06 433.250MHZ 00101 22 434.050MHZ 10101 07 433.300MHZ 00110 23 434.100MHZ 10110 08 433.350MHZ 00111 24 434.150MHZ 10111 09 433.400MHZ 01000 25 434.
6. OPERATING PROCEDURE 6.1. GENERAL OPERATING PROCEDURE 1. Reset the red emergency stop button located on the top left hand side of the transmitter handset by rotating it either clockwise or counter clockwise. The red button will pop up. Figure 11 2. Turn on the transmitter power by inserting the black-colored key into the power key slot located on the top right hand side of the transmitter handset and rotate it clockwise to the “On” position. Figure 12 Figure 13 3.
5. Now press any push button on the transmitter handset to operate the equipment. When a button is pressed, the Status LED will flash orange with a variable speed dependent on how far the button is pressed. The further a button is pressed, the faster the LED will flash. When no buttons are pressed, the Status LED will slowly blink green. 6. In case of an emergency, pressing down on the red emergency stop button will immediately disconnect the receiver E-Stop and turn off the unit.
7.0 RECEIVER MECHANICAL DRAWINGS 7.1.
Figure 18: Mechanical Layout (Flex M-32) Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual April 2012 Page 22 of 42
Figure 19: Example of Flex M Receivers Mounted in an Enclosure 7.2. RECEIVER INSTALLATION 1. Be sure to mount the receiver antenna in direct line-of-sight of the operator and free from all obstructions. 2. Do not mount the receiver near high levels of electric noise, such as an unshielded variable frequency drive, as it may cause minor interference.
7.3. REMOVAL 1. To remove modules from the rail for service, first ensure all power to the Flex M modules has been turned off and proper lockout/tagout procedures have been followed. 2. Remove one end rail clamp and un-nest the module that you wish to remove by separating it from the others on the rail. 3. Use a slotted screwdriver to lift the exposed metal tab/ring on the top of the module. Swing the module down away from the top tab/ring and unhook from the rail. 4.
8. NORMAL OPERATION During the operation of the receiver, following the LED indicators will allow observation of the status of the Flex M receiver. 8.1. POWER SUPPLY MODULE When the Flex M system has power supplied, the two LEDs on the power supply module should be lit and solid. +5VDC CPU – indicates that +5VDC power is going to the CPU +5VDC RELAY – indicates that +5VDC power is going to the RELAY modules 8.2.
Additionally, there are 8 LEDs labeled 1 through 8 on the Analog I/O module. When the LED is on, this indicates that the module is sending/receiving a signal on that input or output.
9. FLEX MODULE TYPES The Flex M system comprises of a RF/CPU module and a power supply module with application-specific add-on cards in-between the CPU module and power supply module. 9.1. FLEX RF/CPU MODULE The Flex RF/CPU Module is the main module that receives radio signals from a paired transmitter and interprets those signals into the appropriate response from the attached I/O modules. There is one RF/CPU module in the Flex M System.
9.2. FLEX M POWER SUPPLY MODULE The Flex M Power Supply Module converts the supply power to 5VDC power for all the attached Flex M modules. This power module has a maximum output supply current of 1000mA. There is one Power Supply Module in the Flex M system.
POWER SUPPLY MODULE OPTIONS Minimum Transformer Power Rating Max Output Current 120VAC Power Supply Module 15VA 1000mA 9-18 VDC @1.5A Power Supply Module 25VA 1500mA 9-36VDC Power Supply Module 15VA 1000mA Description Part Number 25-02-074-804E 25-02-074-810E 25-02-074-820E 9.3. FLEX M RELAY MODULE The Flex M Relay module allows the control of high current power (up to 5A) for attached equipment through 8 relay outputs.
Relay 8 Input Power Relay Output 8 Relay 7 Input Power Relay Output 7 Relay 6 Input Power Relay Output 6 Relay 5 Input Power Relay Output 5 Relays 1-4 Input Power Relay Output 4 Relay Output 3 Relay Output 2 Relay Output 1 Figure 26: Typical Relay Wiring 9.4. FLEX M ANALOG I/O MODULE Outputs: The four analog output signals are able to send voltage signals from 0 to +/-10VDC, at an 8bit resolution. These outputs are for reference voltage only, so each one can only supply 20mA of current.
Figure 27: Analog I/O Module Detail View Analog Input Common Analog Output Common Figure 28: Typical Analog I/O Wiring Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual April 2012 Page 31 of 42
10. RECEIVER CHANNEL CONFIGURATION SETTINGS (Bank 2 on RF/CPU Module) The channel can be set on the RF/CPU module via the Bank 2 dip switches. The following shows the channels or protocols available for each RF/CPU Module option. NOTE: See Section 7.2 for instructions on how to remove the CPU/RF module from the din rail and how to remove the PCB from the module housing.
10.1.
10.2.
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual April 2012 Page 35 of 42
10.3. FCC STATEMENTS 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. Warning (Part 15.21) Changes or modifications not expressly approved by the party responsible for compliance should void the user’s authority to operate the equipment.
11. TROUBLESHOOTING WARNING THE OPERATOR SHOULD NOT ATTEMPT TO REPAIR ANY RADIO CONTROLLER. IF ANY PRODUCT PERFORMANCE OR SAFETY CONCERNS ARE OBSERVED, THE EQUIPMENT SHOULD IMMEDIATELY BE TAKEN OUT OF SERVICE AND BE REPORTED TO THE SUPERVISOR. DAMAGED AND INOPERABLE RADIO CONTROLLER EQUIPMENT SHOULD BE RETURNED TO MAGNETEK FOR EVALUATION AND REPAIR. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT. 11.1.
11.2.
11.3. TROUBLESHOOTING TABLE Problems Possible Reasons Suggestions Transmitter low battery power Check the transmitter battery level. Prior to turning on the transmitter power switch make sure that the red emergency stop button is elevated. Redo the startup procedure by holding the power Improper startup procedure key at “START” position for up to 2.0 seconds and then release. Make sure that the transmitter handset and the Incorrect system RF channel receiver unit both have the same channel.
Problems Receiver responds to the transmitter inconsistently Possible Reasons Suggestions The transmitter is going in and out of range (transmitter and receiver are on the edge of the transmission range) Move the transmitter and the receiver closer together The antenna and/or cable on the receiver is damaged, or improperly installed. The transmitter powered down due to inactivity.
11.4. ASSEMBLY AND REPLACEMENT PARTS Description 433MHz Part 15, version 2 RF/CPU Module 120VAC Power Supply Module 12VDC @ 1.
12.
