FLEX M
Pre-Engineered
(Flex M-16, -24, -32)
Modular Receiver
Part Number: 198-00121 R4
October 2014
© 2014 Magnetek Material Handling
Your New Radio Receiver
Thank you for your purchase of Magnetek’s Enrange
®
brand 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)
Magnetek Material Handling
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
Telephone:
+1.800.288.8178
Website:
E-mail: www.magnetek.com [email protected]
Fax Numbers:
Main:
Sales:
+1.800.298.3503
+1.262.783.3510
Service: +1.262.783.3508
Magnetek, Inc. has additional satellite locations for Canada and the United States. For more information, please visit http://www.magnetek.com.
©2014 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.
TABLE OF CONTENTS
1.0: CRITICAL INSTALLATION CONSIDERATIONS ..................................................................... 3
1.1 GENERAL .............................................................................................................................. 3
1.2 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED EQUIPMENT ................ 3
1.3 SAFETY INFORMATION & RECOMMENDED TRAINING FOR OPERATORS .................. 4
1.4 PRE-OPERATION TEST ....................................................................................................... 5
2.0 FLEX M RECEIVER INSTALLATION ....................................................................................... 6
2.1 PRE-INSTALLATION ............................................................................................................. 6
2.2 MECHANICAL DRAWINGS ................................................................................................... 7
2.3 INSTALLATION ..................................................................................................................... 8
2.4 REMOVAL.............................................................................................................................. 9
3.0 NORMAL OPERATION ........................................................................................................... 10
3.1 POWER SUPPLY MODULE ................................................................................................ 10
3.2 RF/CPU MODULE ............................................................................................................... 10
3.3 RELAY MODULE(S) ............................................................................................................ 10
4.0 FLEX MODULE TYPES .......................................................................................................... 11
4.1 FLEX RF/CPU MODULE ..................................................................................................... 11
4.1.1
Bank 1 Dip Switch Setting Definitions ....................................................................... 11
4.1.1.1
Bank 1 Switches 1 through 5 – Relay configuration program select ................. 11
4.1.1.2
Bank 1 Switch 6 – Invert A/B Select Outputs (Normally OFF) .......................... 11
4.1.1.3
Bank 1 Switch 7 – Auxiliary Relay Output Select (Normally OFF) .................... 12
4.1.1.4
Bank 1 Switch 8 – Disable Tandem (A/B both) Select (Normally OFF) ............ 12
4.1.2
Bank 2 Dip Switch Setting Definitions ....................................................................... 12
4.1.2.1
Bank 2 Switch 1 – AUX 1/2 Output Configuration (Normally ON) ..................... 12
4.1.2.2
Bank 2 Switch 2 – AUX 3/4 Output Configuration (Normally ON) ..................... 12
4.1.2.3
Bank 2 Switch 3 – AUX 5/6 Output Configuration (Normally ON) ..................... 13
4.1.2.4
Bank 2 Switches 4 thru 8 – Radio Frequency channel select ........................... 13
4.2 FLEX M RELAY MODULE ................................................................................................... 13
4.3 FLEX M 120VAC POWER MODULE .................................................................................. 14
5.0 FLEX SYSTEMS – OVERVIEW, SETTINGS AND WIRING DIAGRAMS .............................. 16
5.1 FLEX M-16 SYSTEM OVERVIEW ...................................................................................... 16
5.1.1 Flex M 16 Relay Configuration Settings (Bank 1 on RF/CPU Module) ......................... 16
5.1.2 Flex M 16 Relay Configuration Descriptions ................................................................. 17
5.2 FLEX M-24 SYSTEM OVERVIEW ...................................................................................... 21
5.2.1 Flex M 24 Relay Configuration Settings (Bank 1 on RF/CPU Module) ......................... 21
5.2.2 Flex M 24 Relay Configuration Descriptions ................................................................. 22
5.3 FLEX M-32 SYSTEM OVERVIEW ...................................................................................... 23
5.3.1 Flex M 32 Relay Configuration Settings (Bank 1 on RF/CPU Module) ......................... 23
5.3.2 Flex M 32 Relay Configuration Descriptions ................................................................. 24
6.0 CHANNEL CONFIGURATION SETTINGS (BANK 2 ON RF/CPU MODULE) ....................... 27
6.1 FCC STATEMENTS ............................................................................................................ 27
7.0 TROUBLESHOOTING ............................................................................................................ 28
7.1 TROUBLESHOOTING TABLE ............................................................................................ 29
7.2 ASSEMBLY AND REPLACEMENT PARTS ........................................................................ 31
PRODUCT MANUAL SAFETY INFORMATION
Magnetek, Inc. (Magnetek) offers a broad range of radio remote control products, control products and adjustable frequency drives, and industrial braking systems for overhead material handling applications.
This manual has been prepared by Magnetek to provide information and recommendations for the installation, use, operation and service of Magnetek’s material handling products and systems (Magnetek
Products). Anyone who uses, operates, maintains, services, installs or owns Magnetek Products should know, understand and follow our 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 and lifting devices:
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 overhead material handling industry.
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 owner of the Magnetek Products 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.
WARRANTY INFORMATION
FOR INFORMATION ON MAGNETEK’S PRODUCT WARRANTIES BY PRODUCT TYPE, PLEASE VISIT
WWW.MAGNETEK.COM.
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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.
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1.0: 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 OR DAMAGE TO EQUIPMENT.
1.1 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.
1.2 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED EQUIPMENT
Only properly trained persons designated by management should be permitted to operate radio controlled equipment.
Radio controlled cranes, hoists, lifting devices and other material handling equipment should not be operated by any person who cannot read or understand signs, notices and operating instructions that pertain to the equipment.
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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1.3 SAFETY INFORMATION & RECOMMENDED TRAINING FOR OPERATORS
Anyone being trained to operate radio controlled equipment should possess as a minimum the following knowledge and skills before using the radio controlled equipment.
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 receiver 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 receiver when not in use
be trained in transferring a radio control receiver to another person
be trained how and when to report unsafe or unusual operating conditions
test the receiver 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
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
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.
1.4 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 receiver emergency stop.
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2.0 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.
2.1 PRE-INSTALLATION
1. The 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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2.2 MECHANICAL DRAWINGS
TYPICAL MECHANICAL LAYOUTS
Figure 1: Mechanical Layout
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Flex Flex Flex Flex
Figure 2: Example of Flex M Mounted in an Enclosure
2.3 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 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 2).
6. Do not enclose the antenna in steel. For 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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2.4 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) and then the top housing and PCB can be removed from the lower housing (see Figure 3 for details).
Flex Sys
Figure 3: PCB Removal
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3.0 NORMAL OPERATION
During the operation of the receiver, following the LED indicators will allow observation of the status of the
Flex M receiver.
3.1 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
3.2 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.
- 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
3.3 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 eight LEDs labeled R1 through R8 on the Relay module. When the LED is on, this indicates that the relay is closed/activated.
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4.0 FLEX MODULE TYPES
The Flex M system consists of an RF/CPU module, multiple relay modules and a power supply module.
4.1 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.
Flex
Sys
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 2.4 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 2.4 for details) and set the dip switches as necessary for the Flex
M system utilized (Section 5.0 details switch settings for each Flex system). There are no wires to attach to the RF/CPU module aside from either an antenna or an RF Cable on the TNC antenna connection.
4.1.1 Bank 1 Dip Switch Setting Definitions
The following describes the definitions and functions of the Bank 1 dip switch block on the RF/CPU module:
4.1.1.1 Bank 1 Switches 1 through 5 – Relay configuration program select
These switches can be set per Section 5.0 for the desired relay outputs for the system.
4.1.1.2 Bank 1 Switch 6 – Invert A/B Select Outputs (Normally OFF)
Definition: This feature is only for custom crane relay configurations using A/B select relays.
Programming: Turning bank 1 dip switch position 6 ON (1) inverts the select function operation so that the relay outputs are now normally closed, so when selected, the output will be open.
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4.1.1.3 Bank 1 Switch 7 – Auxiliary Relay Output Select (Normally OFF)
Definition: This feature is only for custom crane relay configurations that have outputs that can be configured as either A/B select or Aux 1/2.
Programming: Turning bank 1 dip switch position 7 OFF (0) sets the outputs to use Aux 1/2 logic.
Turning bank 1 dip switch position 7 ON (1) sets the outputs to use A/B select logic.
4.1.1.4 Bank 1 Switch 8 – Disable Tandem (A/B both) Select (Normally OFF)
Definition: This feature is only for systems that use a tandem selector (or A/B select) logic. This setting is used to disable the tandem (or A/B Both) setting.
Programming: Turning bank 1 dip switch position 8 ON (1) enables tandem (or A/B Both) logic.
Turning bank 1 dip switch position 8 OFF (0) disables tandem (or A/B Both) logic.
4.1.2 Bank 2 Dip Switch Setting Definitions
The following describes the definitions and functions of the Bank 2 dip switch block on the RF/CPU module:
4.1.2.1 Bank 2 Switch 1 – AUX 1/2 Output Configuration (Normally ON)
Definition: This feature sets the Aux 1/2 output relays to be either momentary or latched. When set for momentary outputs, each output will remain on as long as the corresponding button on the transmitter is held. When set for latched outputs, each output will turn on when the corresponding button on the transmitter is pushed, and will turn off when the corresponding button on the transmitter is pushed a second time. The latching setting is not to be used for critical
latching functions, such as magnets. For critical latching functions, an external mechanical latching relay should be used with the radio’s outputs configured as
momentary.
Programming: Turning bank 2 dip switch position 1 OFF (0) sets the Aux 1/2 outputs to latched.
Turning bank 2 dip switch position 1 ON (1) sets the Aux 1/2 outputs to momentary.
4.1.2.2 Bank 2 Switch 2 – AUX 3/4 Output Configuration (Normally ON)
Definition: This feature sets the Aux 3/4 output relays to be either momentary or latched. When set for momentary outputs, each output will remain on as long as the corresponding button on the transmitter is held. When set for latched outputs, each output will turn on when the corresponding button on the transmitter is pushed, and will turn off when the corresponding button on the transmitter is pushed a second time. The latching setting is not to be used for critical
latching functions, such as magnets. For critical latching functions, an external mechanical latching relay should be used with the radio’s outputs configured as
momentary.
Programming: Turning bank 2 dip switch position 2 OFF (0) sets the Aux 3/4 outputs to latched.
Turning bank 2 dip switch position 2 ON (1) sets the Aux 3/4 outputs to momentary.
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Flex Sys
4.1.2.3 Bank 2 Switch 3 – AUX 5/6 Output Configuration (Normally ON)
Definition: This feature sets the Aux 5/6 output relays to be either momentary or latched. When set for momentary outputs, each output will remain on as long as the corresponding button on the transmitter is held. When set for latched outputs, each output will turn on when the corresponding button on the transmitter is pushed, and will turn off when the corresponding button on the transmitter is pushed a second time. The latching setting is not to be used for critical
latching functions, such as magnets. For critical latching functions, an external mechanical latching relay should be used with the radio’s outputs configured as
momentary.
Programming: Turning bank 2 dip switch position 3 OFF (0) sets the Aux 5/6 outputs to latched.
Turning bank 2 dip switch position 3 ON (1) sets the Aux 5/6 outputs to momentary.
4.1.2.4 Bank 2 Switches 4 thru 8 – Radio Frequency channel select
These switches can be set per section 6.0 for the desired operational radio channel frequency for the system.
4.2 FLEX M RELAY MODULE
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. There are typically 2 to 5 relay modules in Flex M systems where the relay module number is set by the rotary switch located on the lower left corner of the board.
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Relay 8
Input Power
Relay 7
Input Power
Relay 6
Input Power
Relay 5
Input Power
Relays 1-4
Input Power
Relay Output 8
Relay Output 7
Relay Output 6
Relay Output 5
Relay Output 4
Relay Output 3
Relay Output 2
Relay Output 1
Figure 4: Typical Relay Wiring
4.3 FLEX M 120VAC POWER MODULE
The Flex M Power Module converts the 120VAC 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 120VAC
Power Module in the Flex M system.
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Not Used
Not Used
Not Used
GND
120VAC (L)
120VAC (L)
120VAC (N)
120VAC (N)
Figure 5: Typical 120VAC 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 2.3. After removing the module from the din rail, press in the tabs as noted above to remove the PCB from the housing.
The fuse 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
1000mA. If additional supply current is required, contact the factory for a custom solution.
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5.0 FLEX SYSTEMS – OVERVIEW, SETTINGS AND WIRING DIAGRAMS
Magnetek offers the Pre-Engineered Flex M systems with the options for 16, 24, and 32 relay outputs.
The following sections describe the overview and wiring diagrams for the Pre-Engineered Flex M systems.
5.1 FLEX M-16 SYSTEM OVERVIEW
FlexM-16 16 output Flex M system with 120VAC power card, RF/CPU card, and two 8 output relay cards.
5.1.1 Flex M 16 Relay Configuration Settings (Bank 1 on RF/CPU Module)
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5.1.2 Flex M 16 Relay Configuration Descriptions
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5.2 FLEX M-24 SYSTEM OVERVIEW
FlexM-24 24 output Flex M system with 120VAC power card, RF/CPU card, and three 8 output relay cards.
5.2.1 Flex M 24 Relay Configuration Settings (Bank 1 on RF/CPU Module)
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5.2.2 Flex M 24 Relay Configuration Descriptions
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5.3 FLEX M-32 SYSTEM OVERVIEW
FlexM-32 32 output Flex M system with 120VAC power card, RF/CPU card, and four 8 output relay cards.
To enable the tandem mode operation in the receiver, dip switch 1-8 needs to be set to the UP position.
When tandem mode operation is enabled, the Motion 3 paddle lever will operate both the Main Hoist
(Motion 3) output and the Aux Hoist (Motion 4) output when the rotary switch on the transmitter is in the tandem position. The Motion 4 paddle lever will be disabled when the rotary switch on the transmitter is in the tandem position. Relay output R4-5 is based solely upon the rotary position on the transmitter and will not be impacted by setting dip switch 1-8 to the DOWN position.
5.3.1 Flex M 32 Relay Configuration Settings (Bank 1 on RF/CPU Module)
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5.3.2 Flex M 32 Relay Configuration Descriptions
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6.0 CHANNEL CONFIGURATION SETTINGS (BANK 2 ON RF/CPU MODULE)
NOTE: See Section 2.4 for instructions on how to remove the CPU/RF module from the Din rail and how to remove the PCB from the module housing.
6.1 FCC STATEMENTS
Compliance Statement (Part 15.19)
This device complies with Part 15 of FCC rules.
Operation is subject to the following two conditions:
1. This device may not cause harmful interference, and
2. This device must accept any interference received, including interference that may cause undesired operation.
Warning (Part 15.21)
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.
Enrange Flex M Pre-Engineered Modular Receiver Manual
October 2014
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7.0 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.
Enrange Flex M Pre-Engineered Modular Receiver Manual
October 2014
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7.1 TROUBLESHOOTING TABLE
Suggestions
Receiver will not turn on, +5VDC
CPU/RELAY LEDs on Power Supply
Module do not light up
Supplied voltage is out of the acceptable range
Internal fuse has blown on power supply module
Internal power supply on
PCB has a problem
Receiver will not respond to the transmitter
Ensure the voltage is 120VAC nominal
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.
Make sure the receiver and transmitter unit are both within range. Also verify that the transmitter is still on.
WDG/Online LED on
CPU/RF module is blinking 1 time (normal operating
WDG), RF MSG LED does
Make sure the receiver and transmitter unit have the same access code. 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.
Make sure the receiver and transmitter are both set to the same channel.
WDG/Online LED on
CPU/RF module is blinking 3 put together; if the problem persists, contact times, read/write error with
Make sure that the modules are securely factory for repair. relay modules
The antenna on the receiver is missing, damaged, or improperly installed.
Inspect the antenna on the receiver for damage and try to locate the antenna in a location that is visible when operating the equipment at all times.
Enrange Flex M Pre-Engineered Modular Receiver Manual
October 2014
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Suggestions
Receiver responds to the transmitter inconsistently
The MLC (Master)
Relay turns off during normal operation
The transmitter is going in and out of range (transmitter
Move the transmitter and receiver closer together and receiver are on the edge of the transmission range)
Relocate the receiver antenna to where it has a better line of sight with the transmitter
The antenna and/or cable on the receiver is damaged, or improperly installed.
Inspect the antenna on the receiver for damage and try to locate the antenna in a location that is visible when operating the equipment at all times.
The transmitter powered down due to inactivity.
Extend the inactivity timeout setting for the transmitter.
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.
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.
Enrange Flex M Pre-Engineered Modular Receiver Manual
October 2014
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7.2 ASSEMBLY AND REPLACEMENT PARTS
900MHz CPU/RF Power Module
120VAC Power Module
Relay Module
900MHz Antenna Kit
Module Replacement Plugs
Arc Suppressor/Snubbers
25-02-074-800E
25-02-074-804E
25-02-074-805E
20-650-0021E
01-300-0031E
20-680-0000E
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October 2014
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