Magnetek Flex 12RS System Instruction manual

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 ................................................................................ 8
2.3. GENERAL ........................................................................................................................................... 8
2.4. PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED CRANES ..................................... 8
2.5. SAFETY INFORMATION AND RECOMMENDED TRAINING FOR RADIO CONTROLLED
EQUIPMENT OPERATORS ...................................................................................................................... 9
2.6. TRANSMITTER UNIT ....................................................................................................................... 10
2.7. PRE-OPERATION TEST .................................................................................................................. 10
2.8. BATTERIES ...................................................................................................................................... 11
2.9. BATTERY HANDLING ...................................................................................................................... 11
2.10. BATTERY CHARGING ................................................................................................................... 11
2.11. BATTERY DISPOSAL ..................................................................................................................... 11
2.12. SPECIFIC SYSTEM WARNINGS ................................................................................................... 12
2.13. FLEX M RECEIVER INSTALLATION .............................................................................................. 12
2.14. PRE-INSTALLATION ...................................................................................................................... 12
3. GENERAL TRANSMITTER INFORMATION ......................................................................................... 13
3.1. EXTERNAL ILLUSTRATION (PRO 12 CONFIGURATION).............................................................. 13
3.2. INTERNAL ILLUSTRATION (PRO 12 CONFIGURATION) ............................................................... 14
3.3. TYPES OF BUTTONS ...................................................................................................................... 15
3.4. ADJUSTABLE SPEED CONTROL ................................................................................................... 15
4. DIP SWITCH SETTINGS ........................................................................................................................ 16
4.1. SYSTEM CHANNEL SETTINGS ...................................................................................................... 16
4.2. INACTIVITY TIME OUT TIMER ........................................................................................................ 17
4.3. A/B/BOTH SELECT .......................................................................................................................... 17
5. SYSTEM CHANNEL TABLE .................................................................................................................. 18
6. OPERATING PROCEDURE ................................................................................................................... 19
6.1. GENERAL OPERATING PROCEDURE ........................................................................................... 19
6.2. CHANGING TRANSMITTER BATTERIES ....................................................................................... 20
7.0 RECEIVER MECHANICAL DRAWINGS .............................................................................................. 21
7.1. MECHANICAL LAYOUTS ................................................................................................................. 21
7.2. RECEIVER INSTALLATION ............................................................................................................. 23
7.3. REMOVAL......................................................................................................................................... 24
8. NORMAL OPERATION .......................................................................................................................... 25
8.1. POWER SUPPLY MODULE ............................................................................................................. 25
8.2. RF/CPU MODULE ............................................................................................................................ 25
8.3. RELAY MODULE(S) ......................................................................................................................... 25
8.4. ANALOG I/O MODULE(S) ................................................................................................................ 25
9. FLEX MODULE TYPES.......................................................................................................................... 27
9.1. FLEX RF/CPU MODULE .................................................................................................................. 27
9.2. FLEX M POWER SUPPLY MODULE................................................................................................ 28
9.3. FLEX M RELAY MODULE ................................................................................................................ 29
9.4. FLEX M ANALOG I/O MODULE ....................................................................................................... 30
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
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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 ........................................................................................................................ 36
11. TROUBLESHOOTING .......................................................................................................................... 37
11.1. TRANSMITTER STATUS LIGHT INDICATORS & WARNINGS ...................................................... 37
11.2. TRANSMITTER PUSH BUTTON ERROR TABLE .......................................................................... 38
11.3. TROUBLESHOOTING TABLE ........................................................................................................ 39
11.4. ASSEMBLY AND REPLACEMENT PARTS .................................................................................... 41
12. NOTES .................................................................................................................................................. 42
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
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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).
Anyone who uses, operates, maintains, services, installs or owns Magnetek Products should know,
understand and follow the instructions and safety recommendations in this manual for Magnetek
Products.
The recommendations in this manual do not take precedence over any of the following requirements
relating to cranes, hoists lifting devices or other material handling equipment which use or include
Magnetek Products:
•
•
•
•
•
Instructions, manuals, and safety warnings of the manufacturers of the equipment where the
radio system is used,
Plant safety rules and procedures of the employers and the owners of facilities where the
Magnetek Products are being used,
Regulations issued by the Occupational Health and Safety Administration (OSHA),
Applicable local, state or federal codes, ordinances, standards and requirements, or
Safety standards and practices for the industries in which Magnetek Products are used.
This manual does not include or address the specific instructions and safety warnings of these
manufacturers or any of the other requirements listed above. It is the responsibility of the owners, users
and operators of the Magnetek Products to know, understand and follow all of these requirements. It is
the responsibility of the employer to make its employees aware of all of the above listed requirements and
to make certain that all operators are properly trained. No one should use Magnetek Products prior to
becoming familiar with and being trained in these requirements and the instructions and safety
recommendations in this manual.
WARRANTY INFORMATION
For information on Magnetek’s product warranties by product type, please visit www.magnetekmh.com.
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
Page 4 of 42
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.SERV
1.866.624.7378
World Headquarters:
Magnetek, Inc.
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
Phone: 1.800.288.8178
Fax:
1.800.298.3503
Magnetek, Inc. has additional satellite locations for Canada and the United States. For more information,
please visit http://www.magnetekmh.com.
©2012 MAGNETEK
All rights reserved. This notice applies to all copyrighted materials included with this product, including,
but not limited to, this manual and software embodied within the product. This manual is intended for the
sole use of the person(s) to whom it was provided, and any unauthorized distribution of the manual or
dispersal of its contents is strictly forbidden. This manual may not be reproduced in whole or in part by
any means whatsoever without the expressed written permission of MAGNETEK.
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
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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.
Each Flex system consists of a transmitter handset and standard-equipped accessories such as a
transmitter waist belt, spare transmitter power key, clear vinyl pouch, “AA” alkaline batteries, compass
direction decal sheet and user’s manual.
List of notable features include:
•
32 user-programmable channels – Advanced synthesized RF controls with 32 built-in
channels; there are no more fixed channel and fragile quartz crystals to break.
•
Over one million unique ID codes (20bit) – Each and every Flex system has its own
unique ID code; no repeats.
•
Advanced controls – The Flex system utilizes advanced microprocessor controls with 16bit CRC which provides ultra-fast, safe, precise, and error-free encoding and decoding.
•
Unique I-CHIP design – The I-CHIP functions in a way that is very similar to SIM cards
used on mobile phones, with the ability to transfer system information and settings from
one transmitter to another without the hassle of resetting the spares.
•
Reliable push buttons – The in-house designed push buttons are rated for more than one
million press cycles.
•
Low power consumption – Requires only two “AA” Alkaline batteries for more than 100
hours of operating time between replacements.
•
Ultra-durable nylon and fiberglass composite enclosures – Highly resistant to
breakage and deformation even in the most abusive environments.
•
Full compliance – All systems are fully compliant with the FCC Part-15 Rules and Industry
Canada Specifications (IC).
•
System Versatility – The Flex PRO/Flex M Radio Control Systems are able to control up
to 4 motions (or 3 motions with A/B Select) with the Flex 8 PRO transmitter or up to 6
motions (or 5 motions with A/B Select) with the Flex 12 PRO transmitter.
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
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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. Warnings are highlighted as shown below:
WARNING
CAUTION – A caution highlights an essential operating or maintenance procedure, practice, etc.
which, if not strictly observed, could result in damage to or destruction of equipment, or loss of
functional effectiveness. Cautions are highlighted as shown below:
CAUTION
WARNINGS and CAUTIONS SHOULD NEVER BE DISREGARDED.
The safety rules in this section are not intended to replace any rules or regulations of any applicable local,
state, or federal governing organizations. Always follow your local lockout and tagout procedure when
maintaining any radio equipment. The following information is intended to be used in conjunction with
other rules or regulations already in existence. It is important to read all of the safety information
contained in this section before installing or operating the Radio Control System.
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
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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.
ALL EQUIPMENT MUST HAVE A MAINLINE CONTACTOR INSTALLED AND ALL TRACKED CRANES, HOISTS,
LIFTING DEVICES, AND SIMILAR EQUIPMENT MUST HAVE A BRAKE INSTALLED. FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
AN AUDIBLE AND/OR VISUAL WARNING MEANS MUST BE PROVIDED ON ALL REMOTE CONTROLLED
EQUIPMENT AS REQUIRED BY CODE, REGULATION, OR INDUSTRY STANDARD. THESE AUDIBLE AND/OR
VISUAL WARNING DEVICES MUST MEET ALL GOVERNMENTAL REQUIREMENTS. FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
FOLLOW YOUR LOCAL LOCKOUT TAGOUT PROCEDURE BEFORE MAINTAINING ANY REMOTE
CONTROLLED EQUIPMENT. ALWAYS REMOVE ALL ELECTRICAL POWER FROM THE CRANE, HOIST, LIFTING
DEVICE, OR SIMILAR EQUIPMENT BEFORE ATTEMPTING ANY INSTALLATION PROCEDURES. DE-ENERGIZE
AND TAGOUT ALL SOURCES OF ELECTRICAL POWER BEFORE TOUCH-TESTING ANY EQUIPMENT. FAILURE
TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
THE DIRECT OUTPUTS OF THIS PRODUCT ARE NOT DESIGNED TO INTERFACE DIRECTLY TO TWO STATE
SAFETY CRITICAL MAINTAINED FUNCTIONS, I.E. MAGNETS, VACUUM LIFTS, PUMPS, EMERGENCY
EQUIPMENT, ETC. A MECHANICALLY LOCKING INTERMEDIATE RELAY SYSTEM WITH SEPARATE POWER
CONSIDERATIONS MUST BE PROVIDED. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS
INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
2.3. GENERAL
Radio controlled material handling equipment operates in several directions. Cranes, hoists, lifting devices, and other
material handling equipment can be large, and operate at high speeds. Quite frequently, the equipment is operated
in areas where people are working in close proximity to the material handling equipment. The operator must
exercise extreme caution at all times. Workers must constantly be alert to avoid accidents. The following
recommendations have been included to indicate how careful and thoughtful actions may prevent injuries, damage to
equipment, or even save a life.
2.4. PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED CRANES
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.
Radio controlled equipment should not be operated by any person with insufficient eyesight or hearing or by any
person who may be suffering from a disorder or illness, is taking any medication that may cause loss of equipment
control, or is under the influence of alcohol or drugs.
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
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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.
The operator should:
•
have knowledge of hazards pertaining to equipment operation
•
have knowledge of safety rules for radio controlled equipment
•
have the ability to judge distance of moving objects
•
know how to properly test prior to operation
•
be trained in the safe operation of the radio transmitter as it pertains to the crane, hoist, lifting device or other
material handling equipment being operated
•
have knowledge of the use of equipment warning lights and alarms
•
have knowledge of the proper storage space for a radio control transmitter when not in use
•
be trained in transferring a radio control transmitter to another person
•
be trained how and when to report unsafe or unusual operating conditions
•
test the transmitter emergency stop and all warning devices prior to operation; testing should be done on
each shift, without a load
•
be thoroughly trained and knowledgeable in proper and safe operation of the crane, hoist, lifting device, or
other material handling equipment that utilizes the radio control
•
know how to keep the operator and other people clear of lifted loads and to avoid “pinch” points
•
continuously watch and monitor status of lifted loads
•
know and follow cable and hook inspection procedures
•
know and follow the local lockout and tagout procedures when servicing radio controlled equipment
•
know and follow all applicable operating and maintenance manuals, safety procedures, regulatory
requirements, and industry standards and codes
The operator shall not:
•
lift or move more than the rated load
•
operate the material handling equipment if the direction of travel or function engaged does not agree with
what is indicated on the controller
•
use the crane, hoist, or lifting device to lift, support or transport people
•
lift or carry any loads over people
•
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
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
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•
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
•
leave power on the radio controlled equipment when the equipment is not in operation
•
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. 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.
2.6. TRANSMITTER UNIT
Transmitter switches should never be mechanically blocked ON or OFF. When not in use, the operator should turn
the transmitter OFF. A secure storage space should be provided for the transmitter unit, and the transmitter unit
should always be placed there when not in use. This precaution will help prevent unauthorized people from operating
the material handling equipment.
Spare transmitters should be stored in a secure storage space and only removed from the storage space after the
current transmitter in use has been turned OFF, taken out of the service area and secured.
2.7. PRE-OPERATION TEST
At the start of each work shift, or when a new operator takes control of the crane, operators should do, as a minimum,
the following steps before making lifts with any crane or hoist:
Test all warning devices.
Test all direction and speed controls.
Test the transmitter emergency stop.
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
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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.
For intrinsically safe environments only use specified Magnetek intrinsically safe batteries.
Keep the battery pack environment cool during charging operation and storage (i.e., not in direct sunlight or close to a
heating source).
2.10. BATTERY CHARGING
For those transmitters equipped with battery chargers, please familiarize all users with the instructions of the charger
before attempting to use.
Do not attempt to charge non-rechargeable battery packs.
Avoid charging partially discharged rechargeable batteries to help prolong battery cycle life.
Avoid charging the battery pack for more than 24 hours at a time.
Do not charge batteries in a hazardous environment.
Do not short the charger.
Do not attempt to charge a damaged battery.
Use only Magnetek approved chargers for the appropriate battery pack.
Do not attempt to use a battery that is leaking, swollen, or corroded.
Charger units are not intended for outdoor use. Use only indoors.
2.11. BATTERY DISPOSAL
Before disposing of batteries consult local and governmental regulatory requirements for proper disposal procedure.
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
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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.
Never operate equipment with two transmitter handsets at the same time unless they are
programmed to do so.
2.13. FLEX M RECEIVER 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.
2.14. PRE-INSTALLATION
1.
2.
3.
4.
5.
Transmitter and receiver access code and channel must match before the system will communicate.
Be aware of other radio channels in the surrounding area - set your system to a unique channel.
Make sure that your equipment is working properly in manual mode prior to system installation.
Make sure the power to the receiver is the correct voltage.
Disconnect equipment power prior to system installation.
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
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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. Pushbuttons #9 - #12 are not present on the Flex 8 PRO Transmitter
2. Pushbutton #7 on the Flex 8PRO and pushbutton #11 on the Flex 12 PRO can be set to
“A / B / BOTH” Select (via dip switch; see Section 4.3)
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
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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.
I-CHIP
Dip-Switch
Battery Contact Mechanism
NOTE: Flex PRO 8 Module will differ slightly
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
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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. To adjust the speed control settings, press and hold the Start button, then press push button 1 or
push button 2 to decrement/increment the range percentage. The red LEDs, which indicate the Speed
Setting, will then change to reflect the current setting.
Start +
Speed control setting
PB1
Decrement Speed Control
PB2
Increment Speed Control
Figure 5
Figure 6
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
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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. Once the transmitter channel is altered, you must set up
the receiver to recognize the transmitters on its new channel.
Top slot → “1”
Bottom slot → “0”
Figure 7
Figure 8
The above dip-switch setting “1 0 0 1 0” corresponds to “channel 19” in the system channels table
(Section 5).
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
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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. A/B/BOTH SELECT
Bit 8 on the dip-switch allows the user to set the lower left pushbutton (PB7 on the Flex 8 PRO, PB11 on
the Flex 12 PRO) into an A / B / BOTH Select button. When the A / B / BOTH Select button is enabled, it
can be used to toggle through the desired outputs as follows: A > B > BOTH > A ...
A / B / BOTH
Dip-switch
Setting
Enabled
1
Disabled
0
Figure 10
NOTE: When A/B Select function is Enabled, A/B LEDs will be OFF at initial startup, but will remain ON
(A, B, or BOTH) once selected. When A/B Select function is disabled, A/B LEDs will remain OFF.
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
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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
434.200MHZ
11000
10
433.450MHZ
01001
26
434.250MHZ
11001
11
433.500MHZ
01010
27
434.300MHZ
11010
12
433.550MHZ
01011
28
434.350MHZ
11011
13
433.600MHZ
01100
29
434.400MHZ
11100
14
433.650MHZ
01101
30
434.450MHZ
11101
15
433.700MHZ
01110
31
434.500MHZ
11110
16
433.750MHZ
01111
32
434.550MHZ
11111
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April 2012
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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.
After turning on the transmitter power, check the Status LED on the transmitter handset for any
sign of system irregularities (refer to Section 11.1). If the system is normal the Status LED will light up
green for two (2) seconds, then slowly flash green.
4.
If there are no signs of any system irregularities, then rotate the power key further clockwise to
the “Start” position for up to 2 seconds. This will activate the receiver E-Stop. Thereafter, the same “Start”
position will become an auxiliary function with momentary contact.
Figure 14
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April 2012
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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. To reset the emergency stop button just rotate the red
button either clockwise or counter-clockwise and then cycle power to the unit.
7.
After a period of inactivity (push button not pressed) defined by the dip switch, the receiver E-Stop
will be disconnected and the unit must cycle power before turning on again.
8.
Turn off the transmitter power by rotating the power key counter-clockwise to the “Off” position
(Status LED becomes a solid red for 4 seconds). This will disconnect the transmitter power and the
receiver E-Stop altogether. Turn it further counter-clockwise to release the key.
6.2. CHANGING TRANSMITTER BATTERIES
Change the transmitter batteries by unscrewing the battery cover located on the backside of the
transmitter (refer to Figures 15 and 16 below). During battery installation make sure that the ribbon is
centered between the two batteries. After changing the batteries also make sure that all screws are
tightened to avoid water, moisture, dirt, grease, or other liquid penetration.
2
1
↓
Figure 15
Figure 16
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7.0 RECEIVER MECHANICAL
DRAWINGS
7.1. MECHANICAL LAYOUTS
Figure 17: Mechanical Layout (Flex M-24)
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Figure 18: Mechanical Layout (Flex M-32)
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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. When mounting the Flex M near unshielded variable
frequency drive, Magnetek typically recommends that the Flex M and all antenna cable routing be
mounted a minimum of 24 inches from all unshielded variable frequency drives and cables.
3.
Allow adequate room for mounting the receiver. Make sure to allow a minimum of 5” between the
connector and nearest surface to allow for cable harness connections.
4.
For best reception and to help protect connectors from moisture and water damage, mount the
receiver in an upright position. Mount with back flush against a flat surface to protect vents from spray.
5.
If obstructions cannot be cleared, or the unit must be mounted inside a metal enclosure, the
remote antenna should be used (see Figure 19).
6.
Do not enclose the antenna in steel. For the best reception, keep all metal objects away from the
antenna. Consult the factory for more information regarding your application.
7.
The supply power to the Flex M system must have a master disconnect and should be fused.
8.
The Flex M modules are installed on a 35mm din rail. To install the individual modules on the din
rail, hook the bottom of the module on the din rail and swing the top of the module to the rail until a click is
heard or felt.
9.
After the modules are placed on the rail, they are slid together so they nest together. Rail clamps
are suggested to prevent the module bundle from sliding freely on the rail.
10.
Modules MUST be installed so that the RF/CPU module is on the left end of the rail and the
power supply module is on the right end of the rail.
NOTE: Magnetek strongly recommends the use of external fuses and circuit disconnects for all Flex
Modules. Consult factory for more information.
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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. The PCB from any module can be removed from its housing by pressing in both tabs first (tabs
are on the front and back sides of the housing); then the top housing and PCB can be removed
from the lower housing (see Figure 20 for details).
Figure 20: Flex M Housing Removal Detail
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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. RF/CPU MODULE
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.
WDG/ONLINE LED:
- Solid indicates RF communication with transmitter
- 1 Blink indicates normal operating WDG
- 2 Blinks indicates RF communication loss with transmitter
- 3 Blinks indicates read/write error to an attached Flex M module
RF MSG LED:
-
-
Fast Blinks indicates radio frequency messages received (typical is 4 to 10
messages per second). This confirms communication between transmitter
and receiver
3 Steady Blinks indicates read/write error to an attached Flex M module
4 Steady Blinks indicates an internal radio error
RF SIGNAL LED – measures the strength of the RF communication signal from the transmitter
8.3. RELAY MODULE(S)
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.
OK LED – Solid indicates module communication with system is good
- 3 Blinks indicates read/write error to attached CPU
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.
8.4. ANALOG I/O MODULE(S)
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 Relay module.
OK LED – Solid indicates module communication with system is good
- 3 Blinks indicates read/write error to attached CPU
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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.
LED1 = Analog Output 1 is Active (non-zero)
LED2 = Analog Output 2 is Active (non-zero)
LED3 = Analog Output 3 is Active (non-zero)
LED4 = Analog Output 4 is Active (non-zero)
LED5 = Analog Input 1 is Active (non-zero)
LED6 = Analog Input 2 is Active (non-zero)
LED7 = Analog Input 3 is Active (non-zero)
LED8 = Analog Input 4 is Active (non-zero)
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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.
Figure 21: RF/CPU Module Detail View
Bank 1 Dip 1 on the dipswitches is used to set the style of transmitter being used. See chart below for
proper settings.
BUTTON SETTING
Dip-switch
Setting
12-Button
1
8-Button
0
RF/CPU MODULE
433MHz Part 15, version 2 RF/CPU Module
25-02-074-816E
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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.
Figure 22: Power Supply Module Detail View
Not Used
Not Used
Not Used
GND
Not Used
120VAC (L)
120VAC (L)
Not Used
Not Used
GND
120VAC (N)
120VAC (N)
Figure 23: Typical 120VAC Power Wiring
(+) VDC
(+) VDC
(-) COM
(-) COM
Figure 24: Typical VDC Power 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 not user serviceable but can be checked if troubleshooting. To check the
fuse, remove the power module from the din rail as described in Section 7.2. After removing the
module from the din rail, press in the tabs as noted above to remove the PCB from the housing.
The fuse is location is shown in the PCB view above. Use a multimeter to check for continuity
across the fuse. If the fuse is blown, contact Magnetek to send the module in for service.
3. The total system Current Consumption should not exceed the Maximum Output Supply Current of
the power supply module. If additional supply current is required, contact the factory for a custom
solution.
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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. Four relays have a common power input and four relays have individually
separate power inputs. The relay module number is set by the rotary switch located on the lower left
corner of the board.
Figure 25: Relay Module Detail View
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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.
The outputs share a common ground reference, which is isolated from the Flex M system ground and any
additional I/O card output ground. These outputs can be preconfigured at the factory for different voltage
ranges (ex. 0-5VDC, or 3-6-9VDC).
Inputs: The four analog input signals are able to receive voltage signals from 0 to +10VDC, at an 8bit
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.
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Figure 27: Analog I/O Module Detail View
Analog Input
Common
Analog Output
Common
Figure 28: Typical Analog I/O Wiring
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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.
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10.1. CHANNEL DIP SWITCH SETTINGS FOR 433MHz PART 15, version 2 RF/CPU MODULE (25-02074-816E)
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10.2. FLEX M 24 AND 32 RELAY PRE-ENGINEERED WIRING
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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.
This portable transmitter with its antenna
complies with FCC’s RF exposure limits for
general population/uncontrolled exposure.
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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. TRANSMITTER STATUS LIGHT INDICATORS & WARNINGS
Type
Display Type
Indication
1
Slow green blink
(Normal Operation)
Transmitter on and in standby.
2
Blinking orange
Button has been pressed and the unit is transmitting.
The speed at which the orange LED blinks is directly
related to how far down the button is pressed.
3
1 red blink followed by a
2-second pause
Voltage goes below 1.9V during operation change batteries immediately.
4
A push button is active while turning on the transmitter.
2 red blinks followed by a
The button that is active will be designated by the (A, B,
2-second pause
25, 100) LEDs. See Push Button Error Table below.
5
3 red blinks followed by a
2-second pause
I-CHIP error.
6
4 red blinks followed by a
2-second pause
Transmitting error, system cannot lock on
to the designated channel.
7
Constant green for up to 2
seconds
Transmitter power on with no faults detected (prior to
initiating the START function).
8
Solid Red
Stop command initiated with receiver
ESTOP deactivated.
9
Solid Red
Voltage goes below 1.9V at initial power on - transmitter
power shuts off.
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11.2. TRANSMITTER PUSH BUTTON ERROR TABLE
A
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
B
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON
25
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
100
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Push Button
1
2
3
4
5
6
7
8
9
10
11
12
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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.
Make sure that the transmitter handset and
Incorrect Receiver Access Code
receiver unit both have the same Receiver
Access Code.
Make sure that the startup procedure is initiated
System out of range
within 100 meters (300 feet) from the receiver
location.
Supplied voltage is out of the
Ensure the voltage is 120VAC nominal
acceptable range
Emergency stop button
activated prior to startup
No response when
transmitter push
button is pressed
(Improper startup &
settings)
Receiver will not turn on,
+5VDC CPU/RELAY
LEDs on Power Supply
Module do not light up
Receiver will not
respond to the
transmitter
Internal fuse has blown on
power supply module
Contact the factory for repair
Internal Power supply on PCB
has a problem
Contact the factory for repair
WDG/Online LED on CPU/RF
module is blinking 2 times
Make sure the receiver and transmitter unit are
both within range. Also verify that the transmitter
(communication loss with
is still on.
transmitter), and RF MSG LED
does not blink.
WDG/Online LED on CPU/RF
module is blinking 1 time
Make sure the receiver and transmitter unit have
(normal operating WDG), RF
the same access code.
MSG LED does not blink and
RF Signal strength LEDs are
indicating a signal strength.
WDG/Online LED on CPU/RF
module is blinking 1 time
Make sure the receiver and transmitter are both
(normal operating WDG), RF
set to the same channel.
MSG LED does not blink and
RF Signal strength LEDs are
indicating an erratic signal.
WDG/Online LED on CPU/RF
Make sure that the modules are securely put
module is blinking 3 times,
together; if the problem persists, contact factory
read/write error with relay
for repair.
modules
The antenna on the receiver is Inspect the antenna on the receiver for damage
missing, damaged, or
and try to place the antenna in a location that is
improperly installed.
visible when operating the equipment at all times.
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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.
Relocate the receiver antenna to where it is in
more line of sight with the transmitter
Inspect the antenna on the receiver for damage
and try to place the antenna in a location that is
visible when operating the equipment at all times.
Extend the inactivity timeout setting for the
transmitter.
The transmitter powered down
Replace the transmitter's batteries.
due to low batteries
The RF/Message LED stops
blinking for more than 3
Radio interference; change the system's channel
setting.
seconds, followed by the MLC
Relay turning off.
The RF/Message LED stopped
The MLC (Master) Relay and the MLC Relay turned off CPU module is resetting. Install snubbers across
turns off during normal
together within 1 sec, possibly
the coils of all contactors to reduce transient
operation
when engaging or disengaging
voltages. Ensure that the power module has a
another relay that is driving a
stable power source.
contactor.
The serial data timeout error
LED (LED #5) on the serial
Error is reset when transmitter issues a start
communication card is lit.
command. Inspect serial communication wiring
Drive serial communication is
to ensure there are no breaks, poor connections
inactive or was inactive for more
or damage to the wiring.
than 1 sec. MLC Relay turned
off together when LED is lit.
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11.4. ASSEMBLY AND REPLACEMENT PARTS
Description
433MHz Part 15, version 2 RF/CPU Module
120VAC Power Supply Module
12VDC @ 1.5A Power Supply Module
9-36VDC Power Supply Module
Relay Module (8 Mechanical relay outputs)
Analog I/O Module (4 0 to +/-10VDC Outputs and 4 0 to +10VDC Inputs)
400MHz Antenna Kit (20’ Cable, Antenna and Bracket)
400MHz Antenna Kit (20’ Cable, 10’ Cable, Antenna & Bracket)
400MHz Antenna Kit (40’ Cable, Antenna and Bracket)
400MHz Antenna Kit (40’ Cable, 10’ Cable, Antenna & Bracket)
NEMA 4 Enclosure, Steel (16”x14”x6”) for Flex M RX, mounted
Module Replacement Plugs
Arc Suppressor/Snubbers
Part Number
25-02-074-816E
25-02-074-804E
25-02-074-810E
25-02-074-820E
25-02-074-805E
25-02-074-806E
178-01377-0530
178-01377-2530
178-01377-0520
178-01377-2520
20-101-0031E
01-300-0031E
20-680-0000E
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12. NOTES
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