Flex M RECEIVER Engineered Modular Receiver Part Number: 198-80104-1100 R0 October 2014 © 2014 Magnetek
Your New Radio Receiver Thank you for your purchase of Magnetek’s Flex M Receiver 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.SERV 1.866.624.7378 International Service: +1.
TABLE OF CONTENTS 1. 2. PRODUCT MANUAL SAFETY INFORMATION ................................................................................ 5 CRITICAL INSTALLATION CONSIDERATIONS ............................................................................... 7 2.1 GENERAL ..................................................................................................................................... 7 2.2 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED EQUIPMENT ....................... 7 2.
10. NOTES .............................................................................................................................................
1. 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.
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.
2.3 SAFETY INFORMATION & RECOMMENDED TRAINING FOR 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 any material handling equipment using a damaged controller because the unit may be unsafe Operate manual motions with other than manual power Operate radio controlled equipment when low battery indicator is on 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.
3. FLEX M INSTALLATION WARNING BEFORE OPERATING THE RECEIVER FAMILIARIZE YOURSELF WITH ALL SAFETY INFORMATION IN THIS MANUAL, APPROPRIATE MANUAL SUPPLEMENTS AND ANY OTHER LOCAL, STATE, OR FEDERAL RULES OR REGULATIONS ALREADY IN EXISTENCE. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT. 3.1 PRE-INSTALLATION 1. Transmitter and receiver access code, channel, and project ID must match before the system will communicate. 2.
3.4 LINE INPUT CONSIDERATIONS WARNING THE UNIT MUST BE WIRED TO THE CORRECT VOLTAGE, AND BE CONNECTED TO THE CORRECT TERMINAL AS REQUIRED BY THE ACTUAL LINE VOLTAGE. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT. Refer to Sections 4.3 and 4.4 for information on how to configure the unit’s power supply modules. NOTE: The receiver unit should not be connected to lines containing excessive power-up transients or continuous commutator noise.
3.6 RECEIVER UNIT ENCLOSURE MOUNTING When mounting the receiver, make sure to allow room for the door to swing open if it is mounted within an enclosure. Mount the receiver unit cabinet securely to the mounting surface. Flex Flex Flex Flex Figure 1. Example of Flex M Mounted in an Enclosure 3.7 RECEIVER INSTALLATION 1. Be sure to mount the receiver antenna in direct line-of-sight of the operator and free from all obstructions. Refer to Section 3.3 for recommendations regarding antenna mounting. 2.
9. Position the receiver; make sure to locate it as far as possible from exposed trolley wire and sources of electromagnetic or radiated noise. 10. Mount the receiver. Refer to Section 3.8 for further information regarding mounting. 11. Wire the unit using the electrical drawings provided with the system. Each section for the modules also indicates how the module should be wired. 12. Wire the power input for the input power type as described in Sections 4.3 and 4.4. 13.
3.9 MECHANICAL DRAWINGS Figure 3.
4. FLEX M MODULES 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. During the operation of the receiver, the LED indicators will allow observation of the status of each of the modules of the Flex M receiver. Refer to each of the sections below for specific information regarding each of the modules.
Figure 5. GEN1 High Power RF/CPU Module Detail View (For RF/CPU modules 900MHz 1W (25-02-074-807E) & 900MHz 200mW (25-02-074-815E) only) The dip switches are used to set the channel and to set relay output type. The dip switches can be accessed by removing the module from the rail (see Section 3.8 for details on how to remove the modules from the rail). After removing the RF/CPU module from the din rail, press in the tabs to release the PCB from the housing (see Section 3.
4.1.1 RF/CPU LED OPERATION When the Flex M system is supplying power to the RF/CPU module, there is a series of LEDs that will indicate the RF/CPU module’s status. Figure 6. GEN1 RF/CPU Module LED Placement WDG/ONLINE LED: o Solid indicates RF communication with transmitter o 1 Blink indicates normal operating WDG o 2 Blinks indicates RF communication loss with transmitter RF MSG LED: o Fast Blinks indicates radio frequency messages received (typical is 4 to 10 messages per second).
4.2 RF/CPU MODULE – GEN 2 This section is applicable to the following RF/CPU module part number(s) with the following format: 198-80104-yRFxxx The “x” in the part number indicates the frequency and power level of the module. The “y” in the part number indicated which RF module type is present (Part 15, Part 90, ETSI). The Flex RF/CPU Module is the main module that receives radio signals from a paired transmitter and interprets those commands into an appropriate response to the attached I/O modules.
Figure 8. GEN2 RF/CPU Module Wiring 4.2.1 RF/CPU LED OPERATION When the Flex M system is supplying power to the RF/CPU module, there is a series of LEDs that will indicate the RF/CPU module’s status. Figure 9.
4.3 POWER SUPPLY MODULE – GEN 1 This section is applicable to the following power supply module part number(s): 25-02-074-804E (120VAC 15VA, 1000mA) 25-02-074-810E (9-18VDC @1.5A 25VA, 1500mA) – No longer available 25-02-074-820E (9-36VDC 15VA, 1000mA) 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. Figure 10.
4.3.1 POWER SUPPLY LED OPERATION When the Flex M system has power supplied, the two LEDs on the power supply module should be lit and solid. Figure 13. GEN1 Power Supply Module LED Placement 4.
Figure 15. GEN2 Power Supply VAC Wiring Figure 16. GEN2 Power Supply VDC Wiring NOTES: 1. Although the power module has built-in protection, Magnetek strongly recommends the use of external fuses and circuit disconnects for all Flex modules. 2. The built-in fuse is user serviceable and can be replaced if blown. To check the fuse, remove the power module from the din rail as described in Section 3.8. Remove the top cover to reveal FH1, the cylindrical fuse holder.
4.4.1 POWER SUPPLY LED OPERATION When the Flex M system has power supplied, the two LEDs on the power supply module should be lit and solid. Figure 17. GEN2 Power Supply Module LED Placement 4.
Figure 18. GEN1 Relay Module Detail View Figure 19.
4.5.1 RELAY MODULE LED OPERATION When the Flex M system is supplying power to the Relay module, there is an LED that indicates the power and communication status of the Relay module. Figure 20. GEN1 Relay Module LED Placement OK LED o Solid indicates module communication with system is good o 3 Blinks indicates read/write error to attached CPU module Additionally, there are 8 LEDs labeled 1 through 8 on the Relay module. When the LED is on, this indicates that the relay is closed/activated. 4.
Figure 21. GEN2 Relay Module Detail View Figure 22.
4.6.1 RELAY MODULE LED OPERATION When the Flex M system is supplying power to the Relay module, there is an LED that indicates the power and communication status of the Relay module. Figure 23. GEN2 Relay Module LED Placement OK LED o Solid indicates module communication with system is good o 3 Blinks indicates read/write error to attached CPU module Additionally, there are 8 LEDs labeled 1 through 8 on the Relay module. When the LED is on, this indicates that the relay is activated. 4.
Figure 24. Serial Communications Module Detail View Figure 25.
4.7.1 SERIAL COMMUNICATION MODULE LED OPERATION When the Flex M system is supplying power to the Serial Communication module, there is an LED that indicates the power and communication status of the Serial Communication module. Figure 26. Serial Communications Module LED Placement OK LED o Solid indicates module communication with system is good o 3 Blinks indicates read/write error to attached CPU module Additionally, there are 8 LEDs labeled 1 through 8 on the Serial Communication module.
Inputs: The four analog input signals are able to receive voltage signals from 0 to +10VDC, at an 8-bit resolution. The input impedance is 20K for these inputs. The inputs share a common ground reference, which is shared with the Flex M system ground. Figure 27. Analog I/O Module Detail View Figure 28.
4.8.1 ANALOG I/O MODULE LED OPERATION When the Flex M system is supplying power to the Analog I/O module, there is an LED that indicates the power and communication status of the Analog I/O module. Figure 29. Analog I/O Module LED Placement OK LED o Solid indicates module communication with system is good o 3 Blinks indicates read/write error to attached CPU module Additionally, there are 8 LEDs labeled 1 through 8 on the Analog I/O module.
4.9 DIGITAL INPUT MODULE – GEN 1 This section is applicable to the following digital input part number(s): 25-02-074-808E (12-24VDC) 25-02-074-817E (50-75VDC) The Flex M Digital Input module allows the reading of twelve digital signals (12-24VDC or 50-75VDC). Custom DC voltage inputs are available upon request. The DC power is not supplied by the card, so a separate power supply needs to be installed to the power inputs.
4.9.1 DIGITAL INPUT MODULE LED OPERATION When the Flex M system is supplying power to the Digital Input module, there is an LED that indicates the power and communication status of the Relay module. Figure 32. GEN1 Digital Input Module LED Placement OK LED o Solid indicates module communication with system is good o 3 Blinks indicates read/write error to attached CPU module Additionally, there are 8 LEDs labeled 1 through 8 on the Digital Input module.
4.10 DIGITAL INPUT MODULE – GEN 2 This section is applicable to the following digital input part number(s): 198-80104-DNPT1 The Flex M Digital Input module allows the reading of eight digital signals. Each of the digital inputs can be configured for a range of 4-36V (Low Range) or 36V-240V (High Range) operation for either AC or DC voltages via a manual jumper connection. Refer to Figure 33 for jumper locations and settings. The input reference voltage is not supplied by the card.
4.10.1 DIGITAL INPUT MODULE LED OPERATION When the Flex M system is supplying power to the Digital Input module, there is an LED that indicates the power and communication status of the Digital Input module. Figure 35. GEN2 Digital Input Module LED Placement OK LED o Solid indicates module communication with system is good o 3 Blinks indicates read/write error to attached CPU module Additionally, there are 8 LEDs labeled 1 through 8 on the Digital Input module.
5. PROGRAMMING WITH RCP Using the optional Radio Control Programmer (RCP) software makes programming of the Flex M 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.
6. RECEIVER CHANNEL CONFIGURATION SETTINGS 6.1 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.
7. GEN 1 RF/CPU CHANNEL DIP SWITCH SETTINGS The channel can be set on the RF/CPU module via the Bank 2 dip switches. The following shows the dip switch settings for each of the channels available for each RF/CPU Module option. NOTE: See section 3.8 for instructions on how to remove the CPU/RF module from the din rail and how to remove the PCB from the module housing. Channel A B C D E F G H I J K L M N O P Q R S T U V W X Frequency 902.30 MHz 904.10 MHz 904.30 MHz 905.10 MHz 905.50 MHz 905.70 MHz 906.
Channel 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 SW4 UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN SW5 UP UP DOWN DOWN UP UP DOWN DOWN UP UP DOWN DOWN UP UP DOWN DOWN UP UP DOWN DOWN UP UP DOWN DOWN UP UP DOWN DOWN UP UP DOWN DOWN SW6 UP UP UP UP DOWN DOWN DOWN DOWN UP UP UP UP DOWN DOWN DOWN DOWN UP UP UP UP DOWN DOWN DOWN DOWN UP UP UP UP DOWN DOWN DOWN DOWN SW7 UP UP UP UP U
Channel 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Frequency 433.000 MHz 433.050 MHz 433.100 MHz 433.150 MHz 433.200 MHz 433.250 MHz 433.300 MHz 433.350 MHz 433.400 MHz 433.450 MHz 433.500 MHz 433.550 MHz 433.600 MHz 433.650 MHz 433.700 MHz 433.750 MHz 433.800 MHz 433.850 MHz 433.900 MHz 433.950 MHz 434.000 MHz 434.050 MHz 434.100 MHz 434.150 MHz 434.200 MHz 434.250 MHz 434.300 MHz 434.350 434.400 434.450 434.500 434.
Channel 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 SW4 DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP SW5 DOWN DOWN UP UP DOWN DOWN UP UP DOWN DOWN UP UP DOWN DOWN UP UP DOWN DOWN UP UP DOWN DOWN UP UP DOWN DOWN UP UP DOWN DOWN UP UP SW6 DOWN DOWN DOWN DOWN UP UP UP UP DOWN DOWN DOWN DOWN UP UP UP UP DOWN DOWN DOWN DOWN UP UP UP UP DOWN DOWN DOWN DOWN UP UP UP UP SW7 DOWN DOWN DOW
Channel AK01 AK02 AK03 AK04 AK05 AK06 AK07 AK08 AK09 AK10 AK11 AK12 AK13 AK14 AK15 AK16 AK17 AK18 AK19 AK20 AKA00 AKA01 AKA02 AKA03 AKA04 AKA05 AKA06 AKA07 AKA08 Frequency 439.8 439.6 439.4 439.2 439.0 438.8 438.6 438.4 438.2 438.0 437.8 437.6 437.4 437.2 437.0 436.8 436.6 436.4 436.2 436.0 433.125 433.325 433.525 433.725 433.925 434.125 434.325 434.525 434.
8. CHANNEL SETS 8.1 433MHZ CHANNEL SET Channel 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Frequency 433.000 MHz 433.050 MHz 433.100 MHz 433.150 MHz 433.200 MHz 433.250 MHz 433.300 MHz 433.350 MHz 433.400 MHz 433.450 MHz 433.500 MHz 433.550 MHz 433.600 MHz 433.650 MHz 433.700 MHz 433.750 MHz 433.800 MHz 433.850 MHz 433.900 MHz 433.950 MHz 434.000 MHz 434.050 MHz 434.100 MHz 434.150 MHz 434.200 MHz 434.250 MHz 434.300 MHz 434.350 MHz 434.400 MHz 434.
8.2 419MHZ CHANNEL SET Channel Frequency Channel Frequency 1* 2* 3* 4* 5* 6* 7* 8* 9* 10* 11* 12* 13* 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 418.950 418.975 419.000 419.025 419.050 419.075 419.100 419.125 419.150 419.175 419.200 419.250 419.275 416.000 416.050 416.100 416.150 416.200 416.250 416.300 416.350 416.400 416.450 416.500 416.550 416.600 416.650 416.700 416.750 416.800 416.850 416.900 416.950 417.000 417.050 417.100 417.150 417.200 417.
8.3 2.4 GHZ: FHSS Channel sets are designated between 1 and 32. The frequency range is between 2402-2478 MHz. The frequency hopping protocol does not use one particular frequency to transmit a message; messages are transmitted over multiple frequencies in a predefined sequence or channel set. In doing so, this protocol is able to compensate for interference that may be present on a single frequency by sending the message across multiple frequencies.
9. 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.
9.1 TROUBLESHOOTING TABLE Problems Possible Reasons Suggestions Supplied voltage is out of the Ensure the input voltage is within the range acceptable range. of the installed power supply module. Receiver will not If it is a Rev 2 module, replace fuse. If fuse turn on, +5VDC Internal fuse has blown on fails again, system troubleshooting is power supply module. required to determine cause. Otherwise CPU/RELAY contact the factory for support.
Problems Drive Connected to Serial Communication Card does not respond Possible Reasons LED #6 is lit up, module is wired in test mode (drive connection is being simulated). The transmitter powered TEST due to inactivity. The transmitter powered TEST due to low batteries. The RF/Message LED stops blinking for more than 3 seconds, followed by the MLC Relay turning off.
10.
