Magnetek Flex PRO, Flex M Radio Control System Instruction Manual
Below you will find brief information for Radio Control System Flex PRO Flex PRO, Radio Control System Flex M Flex M . These 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 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.
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Flex PRO / Flex M Pre-Engineered
Radio Control System
Part Number: 191-00195-1200 R1
August 2016
© 2016 Magnetek Material Handling
TABLE OF CONTENTS
1
INTRODUCTION ................................................................................................................................... 6
2
RADIO CONTROLLED SAFETY .......................................................................................................... 7
2.1
2.2
WARNINGS
AND
CAUTIONS .......................................................................................................... 7
CRITICAL INSTALLATION CONSIDERATIONS ............................................................................ 8
2.3
2.4
2.5
GENERAL ....................................................................................................................................... 8
PERSONS
SAFETY
AUTHORIZED
INFORMATION
TO
AND
OPERATE RADIO
RECOMMENDED
CONTROLLED
TRAINING FOR
CRANES ................................. 8
RADIO CONTROLLED
EQUIPMENT OPERATORS ...................................................................................................................... 9
2.6
2.7
2.8
2.9
TRANSMITTER UNIT ................................................................................................................... 10
PRE-OPERATION TEST .............................................................................................................. 10
HANDLING BATTERIES ............................................................................................................... 10
OPTIONAL RECHARGABLE BATTERY CHARGING .................................................................. 10
CRANE/LIFTING DEVICE SPECIFIC WARNINGS .................................................................. 11
2.10
2.11
2.12
2.13
F
L
EX PRO
FLEX M
SPECIFIC
RECEIVER
SYSTEM WARNINGS ............................................................................... 12
INSTALLATION ........................................................................................ 12
PRE-INSTALLATION ................................................................................................................ 12
3
GENERAL TRANSMITTER INFORMATION ...................................................................................... 13
3.1
3.2
3.3
EXTERNAL
INTERNAL
ILLUSTRATION
ILLUSTRATION
(PRO
(PRO
12
12
CONFIGURATION) .......................................................... 13
CONFIGURATION) ........................................................... 14
TYPES OF BUTTONS .................................................................................................................. 14
4
DIP SWITCH SETTINGS ..................................................................................................................... 15
4.1
4.2
4.3
SYSTEM CHANNEL
INACTIVITY TIME
SETTINGS .................................................................................................. 15
OUT TIMER .................................................................................................... 16
A/B/BOTH SELECT ...................................................................................................................... 16
5
SYSTEM CHANNEL TABLE ............................................................................................................... 17
6
OPERATING PROCEDURE ................................................................................................................ 18
6.1
6.2
GENERAL OPERATING PROCEDURE ....................................................................................... 18
CHANGING TRANSMITTER BATTERIES ................................................................................... 19
7
RECEIVER MECHANICAL DRAWINGS ............................................................................................ 20
7.1
7.2
7.3
MECHANICAL
RECEIVER
LAYOUTS ............................................................................................................. 20
INSTALLATION ......................................................................................................... 22
REMOVAL .................................................................................................................................... 23
8
FLEX MODULE TYPES ...................................................................................................................... 24
8.1
8.2
8.3
8.1.1
RF/CPU MODULE – GEN 2 .......................................................................................................... 26
8.2.1
8.3.1
8.4
RF/CPU
POWER
MODULE
SUPPLY
– GEN 1 .......................................................................................................... 24
RF/CPU LED OPERATION ................................................................................................... 25
RF/CPU LED OPERATION ................................................................................................... 27
MODULE – GEN 1 ........................................................................................... 28
POWER SUPPLY LED OPERATION .................................................................................... 30
8.6
POWER SUPPLY MODULE – GEN 2 ........................................................................................... 30
8.4.1
8.5
8.5.1
8.6.1
POWER SUPPLY LED OPERATION .................................................................................... 32
RELAY
RELAY MODULE LED OPERATION..................................................................................... 34
RELAY
MODULE
MODULE
–
–
GEN
GEN
1 ............................................................................................................ 32
2 ............................................................................................................ 34
RELAY MODULE LED OPERATION..................................................................................... 36
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
August 2016
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8.7
SERIAL COMMUNICATION MODULE ......................................................................................... 36
8.8
8.8.1
ANALOG
I/O MODULE ................................................................................................................. 38
ANALOG I/O MODULE LED OPERATION ........................................................................... 40
9
PROGRAMMING WITH RCP .............................................................................................................. 41
10
RECEIVER CHANNEL CONFIGURATION SETTINGS (BANK 2 ON GEN1 RF/CPU MODULE) 42
10.1
CHANNEL DIP SWITCH SETTINGS FOR 433MH
Z
PART 15,
VERSION
2 RF/CPU MODULE (25-
02-074-816E) ........................................................................................................................................... 43
10.2
10.3
FLEX
FLEX
M
M
24
24
AND
AND
32
32
RELAY
RELAY
PRE-ENGINEERED
PRE-ENGINEERED
WIRING
WIRING
–
–
GEN1
GEN2
M
M
ODULES
ODULES
.......................... 44
.......................... 46
10.4
FCC STATEMENTS .................................................................................................................. 48
11
TROUBLESHOOTING ..................................................................................................................... 49
11.1
11.2
11.3
11.4
TRANSMITTER STATUS LIGHT INDICATORS & WARNINGS .................................................... 49
TRANSMITTER PUSH BUTTON ERROR TABLE ........................................................................ 50
TROUBLESHOOTING TABLE...................................................................................................... 51
ASSEMBLY AND REPLACEMENT PARTS .................................................................................. 53
12
NOTES ............................................................................................................................................. 54
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
August 2016
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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.magnetek.com.
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
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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
International Service
+1.262.783.3500
World Headquarters:
Magnetek, Inc.
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
Telephone: +1.800.288.8178
Website: www.magnetek.com
Email:
Fax Numbers: [email protected]
Main:
Sales:
+1.800.298.3503
+1.262.783.3510
Service:
+1.262.738.3508
Magnetek, Inc. has additional satellite locations for Canada and the United States. For more information, please visit http://www.magnetekmh.com.
© 2016 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
August 2016
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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.
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2 RADIO CONTROLLED SAFETY
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.
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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.
FOLLOW YOUR LOCAL LOCKOUT TAGOUT PROCEDURE BEFORE MAINTAINING ANY REMOTE
CONTROLLED EQUIPMENT. ALWAYS REMOVE ALL ELECTRICAL POWER FROM THE 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.
AFTER INSTALLATION BE SURE TO VERIFY THAT THE TRANSMITTER IS NOT INTERFERING WITH OTHER
EQUIPMENT IN THE AREA. ALSO VERIFY THAT OTHER EQUIPMENT IS NOT INTERFERING WITH THE
TRANSMITTER AND ITS ASSOCIATED EQUIPMENT. FAILURE TO FOLLOW THESE WARNINGS COULD
RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
2.3 GENERAL
Radio controlled equipment operates in several directions. Quite frequently, the equipment is operated in areas where people are working in close proximity to the 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 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.
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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 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 equipment that utilizes the radio control
know how to keep the operator and other people clear of hazardous areas
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:
operate the equipment if the direction of travel or function engaged does not agree with what is indicated on the controller
operate any damaged or malfunctioning equipment
change any settings or controls without authorization and proper training
remove or obscure any warning or safety labels or tags
leave power on the radio controlled equipment when the equipment is not in operation
operate any 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
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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.
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.
At the start of each work shift, or when a new operator takes control of the equipment, operators should do, as a minimum, the following steps before making lifts with any equipment:
Test all warning devices.
Test all functions.
Test the transmitter machine stop.
WARNING
KNOW AND FOLLOW PROPER BATTERY HANDLING, CHARGING 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.
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.
Keep the battery pack environment cool during storage (i.e., not in direct sunlight or close to a heating source).
2.9 OPTIONAL RECHARGABLE BATTERY CHARGING
For those transmitters equipped with rechargeable batteries and battery chargers, all users shall be familiar with the instructions of the charger before attempting to use.
Do not attempt to charge non-rechargeable battery packs in the charger.
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Avoid charging partially discharged rechargeable batteries to help prolong battery cycle life.
Do not charge batteries in a hazardous environment.
Keep the battery pack environment cool during charging (i.e., not in direct sunlight or close to a heating source).
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. Only use charger units indoors.
WARNING
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.
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 OR DAMAGE TO EQUIPMENT.
Cranes, hoists, lifting devices and other material handling equipment can be large, and operate at high speeds.
The operator should:
continuously watch and monitor status of lifted loads
know and follow cable and hook inspection procedures
The operator shall not:
lift or move more than the rated load
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
operate a crane, hoist or lifting device when the device is not centered over the load
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operate a crane, hoist or lifting device if the chain or wire rope is not seated properly in the sprockets, drum or sheave
leave any load unattended while lifted
2.11 FLEX PRO 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.
2.12 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.
2.13 PRE-INSTALLATION
1.
Transmitter and receiver access code and channel must match before the system will communicate.
2.
Be aware of other radio channels in the surrounding area - set your system to a unique channel.
3.
Make sure that your equipment is working properly in manual mode prior to system installation.
4.
Make sure the power to the receiver is the correct voltage.
5.
Disconnect equipment power prior to system installation.
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3 GENERAL TRANSMITTER
INFORMATION
3.1 EXTERNAL ILLUSTRATION (PRO 12 CONFIGURATION)
Figure 1 Figure 2
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
NOTES:
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
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)
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3.2 INTERNAL ILLUSTRATION (PRO 12 CONFIGURATION)
Figure 3 Figure 4
1. Board I-CHIP
Aerial
3.
4.
5
.
Function LED Displays
NOTE: Flex PRO 8 Module will differ slightly
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.
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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 5 below). Only the first five (5) positions of the dip-switch are used for channel programming (refer to Figure 6 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.
Bottom slot → “0”
Figure 5 Figure 6
The above dip-switch setting “1 0 0 1 0” corresponds to “channel 19” in the system channels table
(Section 5).
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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
10 minutes
01
10
15 minutes 11
Never shut off 00
Figure 7
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
Enabled
Disabled
Dip-switch
Setting
1
0
Figure 8
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.
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5 SYSTEM CHANNEL TABLE
Channel Frequency
Dip-switch
Setting
01 433.000MHZ
02 433.050MHZ
03 433.100MHZ
04 433.150MHZ
05 433.200MHZ
06 433.250MHZ
07 433.300MHZ
08 433.350MHZ
09 433.400MHZ
10 433.450MHZ
11 433.500MHZ
12 433.550MHZ
13 433.600MHZ
14 433.650MHZ
15 433.700MHZ
Channel Frequency
Dip-switch
Setting
433.800MHZ
433.850MHZ
433.900MHZ
433.950MHZ
434.000MHZ
434.050MHZ
434.100MHZ
434.150MHZ
434.200MHZ
434.250MHZ
434.300MHZ
434.350MHZ
434.400MHZ
434.450MHZ
434.500MHZ
10000
10001
10010
10011
10100
10101
10110
10111
11000
11001
11010
11011
11100
11101
11110
16 433.750MHZ 01111 32 434.550MHZ 11111
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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 9
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 10 Figure 11
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 12
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.
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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 Figure 13 and Figure 14 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 13 Figure 14
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7 RECEIVER MECHANICAL DRAWINGS
Figure 15: Mechanical Layout (Flex M-24)
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Figure 16: Mechanical Layout (Flex M-32)
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Figure 17: Example of Flex M Receivers Mounted in an Enclosure
1.
2.
3.
4.
5.
Be sure to mount the receiver antenna in direct line-of-sight of the operator and free from all obstructions.
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
.
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.
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.
If obstructions cannot be cleared, or the unit must be mounted inside a metal enclosure, the remote antenna should be used (see Figure 17).
6.
7.
8.
9.
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.
The supply power to the Flex M system must have a master disconnect and should be fused.
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.
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 18 for details).
Figure 18: Flex M Housing Removal Detail
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8 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.
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. Be sure to reference the correct part number for each module type as some of the modules have different versions.
NOTE: It is possible that different generations of Flex M modules may be intermixed. While they are meant to be drop-in replacements some wiring updates may be needed. Refer to the sections below for more information. Also, the installer should make every effort to ensure the wiring gets updated as well as the drawings that are provided with the system. If provided with red-lined drawings, Magnetek can update the system drawings. Additional fees may apply.
8.1 RF/CPU MODULE – GEN 1
This section is applicable to the following RF/CPU module part number(s):
25-02-074-816E (433MHz Part 15)
Identifying a GEN1 CPU module:
The module will contain a label with one of the part numbers listed above
The LED overlay decal will be black
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 for the attached I/O modules. There is one RF/CPU module in the Flex M System.
Figure 19: GEN1 RF/CPU Module Detail View
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 7.3 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 7.3 for details) and set the dip switches as necessary for the Flex M system utilized. There are no wires to attach to the RF/CPU module aside from either an antenna or a coaxial cable on the TNC antenna connection.
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Bank 1 Dip 1 on the dip-switches is used to set the style of transmitter being used. See chart below for proper settings.
BUTTON SETTING
12-Button
Dip-switch
Setting
1
8-Button 0
For channel dip switch settings for each of the different RF types, refer to the appropriate table in Section
10.
8.1.1 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 20: GEN1 RF/CPU Module LED Placement
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). This confirms communication between transmitter and receiver o
3 Steady Blinks indicates read/write error to an attached Flex M module o
4 Steady Blinks indicates an internal radio error
RF SIGNAL LEDs o
Measures the strength of the RF communication signal from the transmitter
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8.2 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 indicates which RF module type is present (Part 15 = 0 or 1, Part 90 = 2, ETSI = 3).
Identifying a GEN2 CPU module:
The module will contain a label with one of the part numbers listed above
The LED overlay decal will be blue
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. There is one
RF/CPU module in the Flex M System.
The software application, Radio Control Programmer (RCP), is used to set the channel, access code, and virtual dip-switches. Communication and configuration is done through J2, the USB connector, which is located opposite the RF connection. In addition to the RF connection to the RP-SMA antenna, the CPU module also contains connections for the E-STOP relays, an auxiliary CAN port, and an external connection for IR communication.
Dip-switch 1 on the virtual dip-switches is used to set the style of transmitter being used. See chart below for proper settings.
BUTTON SETTING
Dip-switch
Setting
12-Button
8-Button
1
0
The E-STOP output consists of two relays in series. These relays can be configured as either NO or NC.
This is set via J8 (NC) or J10 (NO). To configure the output, remove the module as described in Section
7.3 and then reference Figure 21 for the location of jumpers J8 and J10.
The external CAN bus is not intended to be used for communication outside of the receiver system. This is intended for future expansion of the Flex M platform. For CAN bus communication outside of the Flex M receiver system, a communication module will need to be used within the system. Jumper J1 is used to indicate if the CAN bus termination resistor is used or not.
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Figure 21: GEN2 RF/CPU Module Detail View
Figure 22: GEN2 RF/CPU Module Wiring
8.2.1 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 23: GEN2 RF/CPU Module LED Placement
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o
1 Green Blink indicates normal operating WDG o
2 Amber Blinks indicates RF communication loss with transmitter or when the transmitter is powered off o
3 Amber Blinks indicates a read/write error to an attached Flex M module o
6 Amber Blinks indicates that the machine stop has been pressed or that there is an internal machine stop error
RF MSG LED: o
Green Blinks indicates radio frequency messages received. This confirms communication between transmitter and receiver.
RF SIGNAL LEDs: o
Indicates the strength of the RF communication signal from the transmitter. A weak signal is indicated by only the red LEDs illuminated. As the signal strength increases, amber and then green LEDs will light. Green LEDs indicate a strong signal.
E-STOP o
Bicolor LED. Yellow indicator when K1 Relay is active. Green indicator when K2 Relay is active.
8.3 POWER SUPPLY MODULE – GEN 1
This section is applicable to the following power supply module part number(s):
25-02-074-804E (120VAC 60Hz 15VA, 1000mA)
25-02-074-810E (9-18VDC @1.5A 25VA, 1500mA) – No longer available
25-02-074-820E (9-36VDC 15VA, 1000mA)
Identifying a GEN1 Power Supply module:
The module will contain a label with one of the part numbers listed above
The LED overlay decal will be black
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 24: GEN1 Power Supply Module Detail View
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Figure 26: GEN1 Power Supply VDC Wiring Figure 25: GEN1 Power Supply VAC 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 7.3. The fuse location is shown in
Figure 24. 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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8.3.1 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 27: GEN1 Power Supply Module LED Placement
o
Indicates that +5VDC power is going to the CPU
+5VDC o
Indicates that +5VDC power is going to the RELAY modules
8.4 POWER SUPPLY MODULE – GEN 2
This section is applicable to the following power supply module part number(s):
198-80104-PSAC00 (90-250VAC 50/60Hz)
198-80104-PSDC00
198-80104-PSLAC0 (18-56VAC 50/60Hz)
Identifying a GEN2 Power Supply module:
The module will contain a label with one of the part numbers listed above
The LED overlay decal will be blue
All of the Flex M power supply modules convert their input supply power to a nominal 5VDC output for all the attached Flex M modules. This power module has a maximum output supply current of 2000mA
(shared between CPU & relay outputs). There is one power supply module in the Flex M system.
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Figure 28: GEN2 Power Supply Module Detail View
Figure 29: GEN2 Power Supply VAC Wiring Figure 30: 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 7.3. Remove the top cover to reveal FH1, the cylindrical fuse holder. Using a flat-bladed screwdriver, turn the cap a quarter turn counterclockwise, and remove the cap. Use a multimeter to check for continuity across the fuse. If the fuse is blown, replace with a fuse matching the installed specifications.
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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8.4.1 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 31: GEN2 Power Supply Module LED Placement
o
Indicates that +5VDC power is going to the CPU
+5VDC o
Indicates that +5VDC power is going to the RELAY modules
8.5 RELAY MODULE – GEN 1
This section is applicable to the following relay module part number(s):
25-02-074-805E
Identifying a GEN1 Relay module:
The module will contain a label with the part number listed above
The LED overlay decal will be black
The Flex M Relay module allows the control of high current power (up to 5A) for attached equipment through eight 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.
Relays are rated for 10 Amps 277VAC/30VDC, 1 HP 240VAC, but fused for 5A. External suppression for the relays is needed.
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Figure 32: GEN1 Relay Module Detail View
Figure 33: GEN1 Relay Module Wiring
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8.5.1 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 34: GEN1 Relay Module LED Placement
LED o
Solid indicates module communication with system is good o
3 Blinks indicates read/write error to attached CPU module
Additionally, there are eight LEDs labeled 1 through 8 on the Relay module. When the LED is on, this indicates that the relay is closed/activated.
8.6 RELAY MODULE – GEN 2
This section is applicable to the following relay module part number(s):
198-80104-RLY01
Identifying a GEN2 Relay module:
The module will contain a label with the part number listed above
The LED overlay decal will be blue
All output relay contacts are rated for 8 Amps 277VAC/30VDC, 1 HP 240VAC for maximum life and surge protection, and protected with MOVs. Connection to equipment or contactors with higher voltage or current requirements will require intermediate relays.
The Flex M Relay module allows the control of high current power (up to 8A) for attached equipment through eight relay outputs. All eight relays have individual inputs contacts, and two relays (K1 and K2) can be configured manually for either normally open (NO) or normally closed (NC) contacts. To configure
K1 and K2, remove the board as described in Section 7.3, then refer to Figure 35 for the appropriate jumper setting. The relay module number is set by the rotary switch located on the lower left corner of the board.
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Figure 35: GEN2 Relay Module Detail View
Figure 36: GEN2 Relay Module Wiring
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8.6.1 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 37: GEN2 Relay Module LED Placement
LED o
Solid indicates module communication with system is good o
3 Blinks indicates read/write error to attached CPU module
Additionally, there are eight LEDs labeled 1 through 8 on the Relay module. When the LED is on, this indicates that the relay is activated.
8.7 SERIAL
This section is applicable to the following serial communication part number(s):
25-02-074-809E
The Flex M Serial Communication module allows the communication via RS-232 (2-wire only), RS-422 (4wire only), or RS-485 (4-wire only). Any of these interfaces can operate in full duplex, while only RS-232 supports half duplex operation. When operating in full duplex with RS-422 and RS-485, the communication module must always be the master. The communication module can only operate as a slave in half duplex mode.
The Serial Communication module also support CAN-BUS 2.0B.
The Serial Communications module number is set by the rotary switch located on the lower left corner of the board.
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Figure 38: Serial Communications Module Detail View
Figure 39: Serial Communications Module Wiring
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8.8 ANALOG I/O MODULE
This section is applicable to the following analog I/O part number(s):
25-02-074-806E
Outputs:
The four analog output signals are able to send voltage signals from 0 to +/-10VDC, at an 8-bit 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 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 40: Analog I/O Module Detail View
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Figure 41: Analog I/O Module Wiring
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8.8.1 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 42: Analog I/O Module LED Placement
o
Solid indicates module communication with system is good o
3 Blinks indicates read/write error to attached CPU module
Additionally, there are eight 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 o
Analog Output 1 is Active (non-zero)
LED2 o
Analog Output 2 is Active (non-zero)
LED3 o
Analog Output 3 is Active (non-zero)
LED4 o
Analog Output 4 is Active (non-zero)
LED5 o
Analog Input 1 is Active (non-zero)
LED6 o
Analog Input 2 is Active (non-zero)
LED7 o
Analog Input 3 is Active (non-zero)
LED8 o
Analog Input 4 is Active (non-zero)
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9 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. ALL EQUIPMENT OPERATORS AND/OR PERSONNEL SHOULD BE NOTIFIED OF ANY
RADIO DATA VALUE CHANGES THAT MAY AFFECT OPERATION.
Refer to the RCP Users Guide (P/N 178-01702-0010) for information on configuring the Flex M with RCP.
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10 RECEIVER CHANNEL
CONFIGURATION SETTINGS
(Bank 2 on GEN1 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 7.3 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-
02-074-816E)
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10.2 FLEX M 24 AND 32 RELAY PRE-ENGINEERED WIRING – GEN1 MODULES
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10.3 FLEX M 24 AND 32 RELAY PRE-ENGINEERED WIRING – GEN2 MODULES
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10.4 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
Indication
1
3
4
5
6
7
Slow green blink
(Normal Operation)
1 red blink followed by a
2-second pause
2 red blinks followed by a
2-second pause
Transmitter on and in standby.
Button has been pressed and the unit is transmitting. orange related to how far down the button is pressed.
Voltage goes below 1.9V during operation - change batteries immediately.
A push button is active while turning on the transmitter.
The button that is active will be designated by the (A, B,
25, 100) LEDs. See the following Push Button Error
Table
.
3 red blinks followed by a
2-second pause
I-CHIP error.
4 red blinks followed by a
2-second pause
Constant green for up to 2 seconds
Transmitting error, system cannot lock on to the designated channel.
Transmitter power on with no faults detected (prior to initiating the START function).
Stop command initiated with receiver
ESTOP deactivated.
Voltage goes below 1.9V at initial power on - transmitter power shuts off.
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11.2 TRANSMITTER PUSH BUTTON ERROR TABLE
OFF OFF OFF ON
OFF OFF ON OFF
OFF OFF ON ON
OFF ON OFF OFF
1
2
3
4
OFF ON OFF ON
OFF ON ON OFF
OFF ON ON ON
ON OFF OFF OFF
ON OFF OFF ON
ON OFF ON OFF
5
6
7
8
9
10
ON OFF ON ON 11
ON ON OFF OFF 12
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TABLE
Suggestions
No response when transmitter push button is pressed
(Improper startup & settings)
Transmitter low battery power Check the transmitter battery level.
Emergency stop button activated prior to startup
Improper startup procedure
Incorrect system RF channel
Incorrect Receiver Access Code
System out of range
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 key at “START” position for up to 2.0 seconds and then release.
Make sure that the transmitter handset and the receiver unit both have the same channel.
Make sure that the transmitter handset and receiver unit both have the same Receiver
Access Code.
Make sure that the startup procedure is initiated within 100 meters (300 feet) from the receiver location.
Supplied voltage is out of the acceptable range
Ensure the voltage is 120VAC nominal.
Receiver will not turn on,
+5VDC CPU/RELAY
LEDs on Power Supply
Module do not light up
Internal fuse has blown on power supply module
Internal Power supply on PCB has a problem
Receiver will not respond to the transmitter
Contact the factory for repair.
Contact the factory for repair.
WDG/Online LED on CPU/RF module is blinking 2 times
(communication loss with transmitter), and RF MSG LED does not blink.
WDG/Online LED on CPU/RF module is blinking 1 time
(normal operating WDG), RF
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
(normal operating WDG), RF
MSG LED does not blink and
RF Signal strength LEDs are indicating an erratic signal.
WDG/Online LED on CPU/RF module is blinking 3 times, read/write error with relay modules
The antenna on the receiver is missing, damaged, or improperly installed.
Make sure the receiver and transmitter unit are both within range. Also verify that the transmitter is still on.
Make sure the receiver and transmitter unit have the same access code.
Make sure the receiver and transmitter are both set to the same channel.
Make sure that the modules are securely put together; if the problem persists, contact factory for repair.
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.
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Suggestions
Receiver responds to the transmitter inconsistently
The transmitter is going in and out of range (transmitter and receiver are on the edge of the transmission range)
The antenna and/or cable on the receiver is damaged, or improperly installed.
The transmitter powered down due to inactivity.
Move the transmitter and the receiver closer together.
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 MLC (Master) Relay turns off during normal operation
The transmitter powered down due to low batteries.
The RF/Message LED stops blinking for more than 3 seconds, followed by the MLC
Relay turning off.
The RF/Message LED stopped and the MLC Relay turned off together within 1 sec, possibly when engaging or disengaging another relay that is driving a contactor.
The serial data timeout error
LED (LED #5) on the serial communication card is lit.
Drive serial communication is inactive or was inactive for more than 1 sec. MLC Relay turned off together when LED is lit.
Replace the transmitter's batteries.
Radio interference; change the system's channel setting.
CPU module is resetting. Install snubbers across the coils of all contactors to reduce transient voltages. Ensure that the power module has a stable power source.
Error is reset when transmitter issues a start command. Inspect serial communication wiring to ensure there are no breaks, poor connections or damage to the wiring.
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11.4 ASSEMBLY AND REPLACEMENT PARTS
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
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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Key features
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- Full compliance with FCC and Industry Canada Specifications