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Flex M
User Manual
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Magnetek Flex M User Manual

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Page 1
Flex M RECEIVER
Engineered
Modular Receiver
Part Number: 198-80104-1100 R05
May 2019
© 2019 Magnetek
Page 2
SERVICE INFORMATION
Canada Service Information:
EU Market Contact:
Your New Radio Remote Control System
Thank you for your purchase of Magnetek’s Flex M Receiver Radio Remote Equipment Control. Magnetek has set a whole new standard in radio-remote performance, dependability, and value with this line of modular receivers.
If your product ever needs modification or service, please contact one of our representatives at the following locations:
U.S. Service Information
For questions regarding service or technical information contact: 1-866-MAG-SERV (1-866-624-7378)
International Service
262-783-3500
World Headquarters:
Magnetek, Inc. N49 W13650 Campbell Drive Menomonee Falls, WI 53051
Telephone: 800-288-8178 Website: www.magnetek.com E-mail: [email protected]
Fax Numbers:
Main: 800-298-3503 Sales: 262-783-3510 Service: 262-783-3508
161 Orenda Road Unit 1 Brampton, Ontario L6W 1W3 Canada Phone: 800-792-7253 Fax: 905-828-5707 416-424-7617 (24/7 Service pager)
© 2019 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.
Brian Preston Magnetek (UK) Ltd. Unit 3 Bedford Business Centre Mile Road Bedford, MK42 9TW UK Phone: +44-1234-349191
May 2019
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TABLE OF CONTENTS
1. PRODUCT MANUAL SAFETY INFORMATION ................................................................................ 5
2. CRITICAL INSTALLATION CONSIDERATIONS ............................................................................... 7
2.1 GENERAL ..................................................................................................................................... 7
2.2 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED EQUIPMENT ....................... 7
2.3 SAFETY INFORMATION & RECOMMENDED TRAINING FOR OPERATORS .......................... 8
2.4 PRE-OPERATION TEST .............................................................................................................. 9
3. FLEX M INSTALLATION .................................................................................................................. 10
3.1 ENVIRONMENTAL ..................................................................................................................... 10
3.2 PRE-INSTALLATION .................................................................................................................. 10
3.3 RECEIVER UNIT MOUNTING LOCATION CONSIDERATIONS ............................................... 10
3.4 ANTENNA MOUNTING CONSIDERATIONS ............................................................................. 10
3.5 LINE INPUT CONSIDERATIONS ............................................................................................... 11
3.6 WIRING CONSIDERATION ........................................................................................................ 11
3.7 RECEIVER UNIT ENCLOSURE MOUNTING ............................................................................ 12
3.8 RECEIVER INSTALLATION ....................................................................................................... 12
3.9 REMOVAL ................................................................................................................................... 13
3.10 MECHANICAL DRAWINGS ........................................................................................................ 14
4. FLEX M MODULES .......................................................................................................................... 15
4.1 RF/CPU MODULE – GEN 1 ........................................................................................................ 15
4.1.1 RF/CPU LED OPERATION ................................................................................................. 17
4.2 RF/CPU MODULE – GEN 2 ........................................................................................................ 18
4.2.1 RF/CPU LED OPERATION ................................................................................................. 19
4.3 POWER SUPPLY MODULE – GEN 1 ........................................................................................ 20
4.3.1 POWER SUPPLY LED OPERATION ................................................................................. 21
4.4 POWER SUPPLY MODULE – GEN 2 ........................................................................................ 21
4.4.1 POWER SUPPLY LED OPERATION ................................................................................. 23
4.5 RELAY MODULE – GEN 1 ......................................................................................................... 23
4.5.1 RELAY MODULE LED OPERATION .................................................................................. 25
4.6 RELAY MODULE – GEN 2 ......................................................................................................... 25
4.6.1 RELAY MODULE LED OPERATION .................................................................................. 27
4.7 SERIAL COMMUNICATION MODULE ....................................................................................... 27
4.7.1 SERIAL COMMUNICATION MODULE LED OPERATION ................................................ 29
4.8 ANALOG I/O MODULE ............................................................................................................... 29
4.8.1 ANALOG I/O MODULE LED OPERATION ......................................................................... 31
4.9 DIGITAL INPUT MODULE – GEN 1 ........................................................................................... 32
4.9.1 DIGITAL INPUT MODULE LED OPERATION .................................................................... 33
4.10 DIGITAL INPUT MODULE – GEN 2 ........................................................................................... 34
4.10.1 DIGITAL INPUT MODULE LED OPERATION .................................................................... 35
5. PROGRAMMING WITH RCP .......................................................................................................... 37
6. RECEIVER CHANNEL CONFIGURATION SETTINGS .................................................................. 38
6.1 FCC STATEMENTS .................................................................................................................... 38
7. GEN 1 RF/CPU CHANNEL DIP SWITCH SETTINGS .................................................................... 39
8. CHANNEL SETS .............................................................................................................................. 44
8.1 433MHz CHANNEL SET ............................................................................................................. 44
8.2 419MHz CHANNEL SET ............................................................................................................. 45
8.3 2.4 GHz: FHSS............................................................................................................................ 46
9. TROUBLESHOOTING ..................................................................................................................... 47
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9.1 TROUBLESHOOTING TABLE .................................................................................................... 48
10. EU DECLARATION OF CONFORMITY .......................................................................................... 50
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1. PRODUCT MANUAL SAFETY INFORMATION

Magnetek, Inc. (Magnetek) offers a broad range of radio remote control products, control products and adjustable frequency drives, and industrial braking systems for overhead material handling applications. This manual has been prepared by Magnetek to provide information and recommendations for the installation, use, operation and service of Magnetek’s material handling products and systems (Magnetek Products). 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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2. CRITICAL INSTALLATION CONSIDERATIONS

WARNING

PRIOR TO INSTALLATION AND OPERATION OF THIS EQUIPMENT, READ AND DEVELOP AN UNDERSTANDING OF THE CONTENTS OF THIS MANUAL AND THE OPERATION MANUAL OF THE EQUIPMENT OR DEVICE TO WHICH THIS EQUIPMENT WILL BE INTERFACED. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
ALL EQUIPMENT MUST HAVE A MAINLINE CONTACTOR INSTALLED AND ALL TRACKED CRANES, HOISTS, LIFTING DEVICES AND SIMILAR EQUIPMENT MUST HAVE A BRAKE INSTALLED. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
AN AUDIBLE AND/OR VISUAL WARNING MEANS MUST BE PROVIDED ON ALL REMOTE CONTROLLED EQUIPMENT AS REQUIRED BY CODE, REGULATION, OR INDUSTRY STANDARD. THESE AUDIBLE AND/OR VISUAL WARNING DEVICES MUST MEET ALL GOVERNMENTAL REQUIREMENTS. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
FOLLOW YOUR LOCAL LOCKOUT TAGOUT PROCEDURE BEFORE MAINTAINING ANY REMOTE CONTROLLED EQUIPMENT. ALWAYS REMOVE ALL ELECTRICAL POWER FROM THE CRANE, HOIST, LIFTING DEVICE OR SIMILAR EQUIPMENT BEFORE ATTEMPTING ANY INSTALLATION PROCEDURES. DE­ENERGIZE 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.

2.1 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.

2.2 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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2.3 SAFETY INFORMATION & RECOMMENDED TRAINING FOR OPERATORS

Anyone being trained to operate radio controlled equipment should possess as a minimum the following knowledge and skills before using the radio controlled equipment.
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
• Operate a crane, hoist, or lifting device if the chain or wire rope is not seated properly in the
sprockets, drum or sheave
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• Operate any damaged or malfunctioning crane, hoist, lifting device or other material handling equipment
• Change any settings or controls without authorization and proper training
• Remove or obscure any warning or safety labels or tags
• Leave any load unattended while lifted
• Leave power on the radio controlled equipment when the equipment is not in operation
• Operate any material handling equipment using a damaged controller because the unit may be
unsafe
• Operate manual motions with other than manual power
• Operate radio controlled equipment when low battery indicator is on

WARNING

THE OPERATOR SHOULD NOT ATTEMPT TO REPAIR ANY RADIO CONTROLLER. IF ANY PRODUCT PERFORMANCE OR SAFETY CONCERNS ARE OBSERVED, THE EQUIPMENT SHOULD IMMEDIATELY BE TAKEN OUT OF SERVICE AND BE REPORTED TO THE SUPERVISOR. DAMAGED AND INOPERABLE RADIO CONTROLLER EQUIPMENT SHOULD BE RETURNED TO MAGNETEK FOR EVALUATION AND REPAIR. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

2.4 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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3. FLEX M INSTALLATION

WARNING

BEFORE OPERATING THE RECEIVER FAMILIARIZE YOURSELF WITH ALL SAFETY INFORMATION IN THIS MANUAL, APPROPRIATE MANUAL SUPPLEMENTS AND ANY OTHER LOCAL, STATE, OR FEDERAL RULES OR REGULATIONS ALREADY IN EXISTENCE. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

3.1 ENVIRONMENTAL

1. Operating Temperature: -30°C to +70°C (-22° F to +158° F) ambient.
2. Humidity: up to 95% (non-condensing).

3.2 PRE-INSTALLATION

1. Transmitter and receiver access code, frequency, channel, and project ID 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 and current.
5. Disconnect equipment power prior to system installation.

3.3 RECEIVER UNIT MOUNTING LOCATION CONSIDERATIONS

Ensure the mounting location is as far as possible from exposed trolley wires and sources of electromagnetic or radiated noise as possible.
The mounting surface must be smooth and continuous. Mounting the receiver unit on uneven surfaces could cause warping or stress internal components.
If possible, avoid installing the receiver unit to a surface where high vibration or shock is present. If this cannot be avoided, use appropriate shock mounts.

3.4 ANTENNA MOUNTING CONSIDERATIONS

It is best to mount the antenna so that it is visible to the operator. This is usually accomplished by mounting the antenna under the crane. However, it is not recommended to point the antenna straight down, as this will cause a “dead” spot directly under the antenna. The antenna should be mounted at a 45-degree angle in relation to the operator. Always try to avoid power sources, motors, drives, brakes, etc., when installing the antenna. If necessary, Magnetek offers an external antenna kit.
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3.5 LINE INPUT CONSIDERATIONS

WARNING

THE UNIT MUST BE WIRED TO THE CORRECT VOLTAGE, AND BE CONNECTED TO THE CORRECT TERMINAL AS REQUIRED BY THE ACTUAL LINE VOLTAGE. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

Refer to Sections 4.3 and 4.4 for information on how to configure the unit’s power supply modules.
NOTE: The receiver unit should not be connected to lines containing excessive power-up transients or continuous commutator noise. A line conditioner may be necessary in some installations.

3.6 WIRING CONSIDERATION

1. Read this manual before installation.
2. Please observe appropriate local and National Electrical Codes when wiring electrical devices.
3. Do not connect/disconnect wiring or perform circuit checks while the power is turned on.
4. The motor wiring and the power wiring should also be in separate metal conduits.
5. Low voltage wires shall be wired with proper low voltage class wiring procedures.
6. Control wiring as well as antenna wiring shall be in separate conduit and shall be kept as short as
possible.
7. All terminals shall be tightened to specified terminal torque between 4.4 IN-LBS (.5 N·m) and 5.3
IN-LBS (.6 N·m), unless otherwise specified.
8. Remove excess metal screws, metal filings, and wire clippings from inside of unit.
9. Inspect to make sure no exposed wire has contact with any other wiring or terminals.
10. RC type suppressors are strongly recommended on all contactors.
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3.7 RECEIVER UNIT ENCLOSURE MOUNTING

Flex
Flex
Flex
Flex
Figure
When mounting the receiver, make sure to allow room for the door to swing open if it is mounted within an enclosure. Mount the receiver unit cabinet securely to the mounting surface.
1. Example of Flex M Mounted in an Enclosure

3.8 RECEIVER INSTALLATION

1. Be sure to mount the receiver antenna in direct line-of-sight of the operator and free from all
obstructions. Refer to Section 3.4 for recommendations regarding antenna mounting.
2. Do not mount the receiver near high levels of electrical noise, such as unshielded variable
frequency drives, as they may cause minor interference. When mounting the Flex M near unshielded variable frequency drives 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. Be sure to allow a minimum of 5” between the
connector and nearest surface to allow for cable harness connections.
4. For best reception, and to help protect connectors from moisture and water damage, mount the
receiver in an upright position.
5. If obstructions cannot be cleared, or if the unit must be mounted inside of a metal enclosure, the
remote antenna should be used.
6. Do not enclose the antenna in steel. If the receiver is mounted within an enclosure, an external
antenna MUST be used. For the best reception, keep all metal objects away from the antenna. Consult the factory for more information regarding your application.
7. The power source to the Flex M system must have a master disconnect and should be fused.
8. It should not be necessary to set the Access Code or channel, as they are preset. If special field
programming is needed, power the unit up on the bench and program the unit for any special configurations or other parameters (see Section 5 for details). The unit can be re-programmed after it is installed if necessary.
9. Position the receiver; make sure to locate it as far as possible from exposed trolley wire and
sources of electromagnetic or radiated noise.
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10. Mount the receiver. Refer to Section 3.3 for further information regarding mounting.
11. Wire the unit using the electrical drawings provided with the system. Each section for the
modules also indicates how the module should be wired.
12. Wire the power input for the input power type as described in Sections 4.3 and 4.4.
13. Wiring of the system should now be complete. Install the antenna.
14. If there are any problems, refer to Section 9.

3.9 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 DIN rail release tab on the top of the module. Swing the
module down and 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 below for details).
Figure 2. Flex M Housing Removal Detail
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3.10 MECHANICAL DRAWINGS

Figure 3. Example Flex M Mechanical Layout
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4. FLEX M MODULES

The Flex M system comprises of a RF/CPU module and a power supply module with application specific add-on cards in between the CPU module and power supply module.
During the operation of the receiver, the LED indicators will allow observation of the status of each of the modules of the Flex M receiver. Refer to each of the sections below for specific information regarding each of the modules. 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 will 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. In addition, the installer should make every effort to ensure the wiring is updated as well as the drawings that are provided with the system. If provided with redlined drawings, Magnetek can update the system drawings. Additional fees may apply.

4.1 RF/CPU MODULE – GEN 1

This section is applicable to the following RF/CPU module part number(s):
• 25-02-074-800E (900MHz Part 15)
• 25-02-074-801E (400MHz Legacy Communication)
• 25-02-074-807E (900MHz 1W) – No longer available
• 25-02-074-815E (900MHz 200mW) – No longer available
• 25-02-074-816E (433MHz Part 15)
• 25-02-074-818E (2.4GHz 50mW)
• 25-02-074-819E (2.4GHz 125mW)
• 25-02-074-821E (400-420MHz)
• 25-02-074-822E (410-430MHz)
NOTE: The high power RF/CPU Module 25-02-074-807E draws up to 1300mA of power when in use. It requires the high current power supply module 25-02-074-810E to perform properly.
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.
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Figure 4. GEN1 RF/CPU Module Detail View
(For all RF/CPU modules except 900MHz 1W (25-02-074-807E) and 900MHz 200mW (25-02-074-815E))
Figure 5. GEN1 High Power RF/CPU Module Detail View
(For RF/CPU modules 900MHz 1W (25-02-074-807E) and 900MHz 200mW (25-02-074-815E) only)
The dip switches are used to set the channel and to set relay output type. The dip switches can be accessed by removing the module from the rail (see Section 3.9 for details on how to remove the modules from the rail). After removing the RF/CPU module from the din rail, press in the tabs to release the PCB from the housing (see Section 3.9 for details) and set the dip switches as necessary for the Flex M system utilized (refer to the project drawings for any specifics). 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.
For channel dip switch settings for each of the different RF types, refer to the appropriate table in Section
7.
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4.1.1 RF/CPU LED OPERATION

When the Flex M system supplies power to the RF/CPU module, there is a series of LEDs that indicate the RF/CPU module’s status.
Figure 6. GEN1 RF/CPU Module LED Placement
• WDG/ONLINE LED:
o Solid indicates RF communication with transmitter o 1 Blink indicates normal operating WDG o 2 Blinks indicates RF communication loss with transmitter
• RF MSG LED:
o Fast Blinks indicates radio frequency messages received (typical frequency 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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4.2 RF/CPU MODULE – GEN 2

This section is applicable to the following RF/CPU module part number(s) with the following format:
• 198-80104-yRFxxx
The “x” in the part number indicates the frequency and power level of the module. The “y” in the part number 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.
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
3.9 and then reference Figure 7 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.
Figure 7. GEN2 RF/CPU Module Detail View
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Figure 8. GEN2 RF/CPU Module Wiring

4.2.1 RF/CPU LED OPERATION

When the Flex M system supplies power to the RF/CPU module, there is a series of LEDs that indicate the RF/CPU module’s status.
• WDG/ONLINE LED:
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 LED
o Bicolor LED. Yellow indicator when K1 Relay is active. Green indicator when K2 Relay is
active
Figure 9. GEN2 RF/CPU Module LED Placement
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4.3 POWER SUPPLY MODULE – GEN 1

This section is applicable to the following power supply module part number(s):
• 25-02-074-804E (120VAC 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 10. GEN1 Power Supply Module Detail View
Figure 11. GEN1 Power Supply VAC Wiring
Figure 12. GEN1 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 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 3.9. The fuse location is shown in Figure 10. Use a multimeter to check for continuity across the fuse. If the fuse is blown, contact Magnetek to send the module in for service.
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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.

4.3.1 POWER SUPPLY LED OPERATION

When the Flex M system has power supplied, the two LEDs on the power supply module should be lit and solid.
Figure 13. GEN1 Power Supply Module LED Placement
• +5VDC CPU
o Indicates that +5VDC power is going to the CPU
• +5VDC RELAY
o Indicates that +5VDC power is going to the RELAY modules

4.4 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 (6-36VDC)
• 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 and relay outputs). There is one power supply module in the Flex M system.
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Figure 14. GEN2 Power Supply Module Detail View
Figure 15. GEN2 Power Supply VAC Wiring
Figure 16. GEN2 Power Supply VDC Wiring
NOTES:
1. Although the power module has built-in protection, Magnetek strongly recommends the use of
external fuses and circuit disconnects for all Flex modules.
2. The built-in fuse is user serviceable and can be replaced if blown. To check the fuse, remove the
power module from the din rail as described in Section 3.9. 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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May 2019
Page 23

4.4.1 POWER SUPPLY LED OPERATION

When the Flex M system has power supplied, the two LEDs on the power supply module should be lit and solid.
Figure 17. GEN2 Power Supply Module LED Placement
• +5VDC CPU
o Indicates that +5VDC power is going to the CPU
• +5VDC RELAY
o Indicates that +5VDC power is going to the RELAY modules

4.5 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 rotary switch located on the lower left corner of the board sets the relay module number.
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 18. GEN1 Relay Module Detail View
Figure 19. GEN1 Relay Module Wiring
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4.5.1 RELAY MODULE LED OPERATION

When the Flex M system is supplying power to the Relay module, an LED indicates the power and communication status of the Relay module.
Figure 20. GEN1 Relay Module LED Placement
• OK LED
o Solid indicates module communication with system is good o 3 Blinks indicates read/write error to attached CPU module
Additionally, there are eight LEDs labeled 1 through 8 on the Relay module. When the LED is on, this indicates that the relay is closed/activated.

4.6 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 3.9, then refer to Figure 21 for the appropriate jumper setting. The rotary switch located on the lower left corner of the board sets the relay module number.
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Figure 21. GEN2 Relay Module Detail View
Figure 22. GEN2 Relay Module Wiring
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4.6.1 RELAY MODULE LED OPERATION

When the Flex M system is supplying power to the Relay module, an LED indicates the power and communication status of the Relay module.
Figure 23. GEN2 Relay Module LED Placement
• OK LED
o Solid indicates module communication with system is good o 3 Blinks indicates read/write error to attached CPU module
Additionally, there are eight LEDs labeled 1 through 8 on the Relay module. When the LED is on, this indicates that the relay is activated.

4.7 SERIAL COMMUNICATION MODULE

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 24. Serial Communications Module Detail View
Figure 25. Serial Communications Module Wiring
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4.7.1 SERIAL COMMUNICATION MODULE LED OPERATION

When the Flex M system is supplying power to the Serial Communication module, an LED indicates the power and communication status of the Serial Communication module.
Figure 26. Serial Communications Module LED Placement
• OK LED
o Solid indicates module communication with system is good o 3 Blinks indicates read/write error to attached CPU module
Additionally, there are eight LEDs labeled 1 through 8 on the Serial Communication module.
• When LED number 1 is steady, this indicates an internal CAN bus initialization error.
• When LED number 2 is steady, this indicates an external CAN bus initialization error.
• When LED number 2 is blinking, this indicates message reception on the external CAN bus.
• When LED number 3 is blinking, this indicates that the Serial Communication Card is
communicating with the attached drive. This is only applicable for RDSI systems.
• When LED number 5 is on steady, this indicates there is a serial communication time-out error
(the serial communication was inactive for 1 second). See Section 9 for additional information.
• When LED number 6 is on steady, this indicates that the Serial Communication is in test mode.
• When LED number 7 is on steady, this indicates that the CPU module is sending a drive forward
command. This is only applicable for RDSI systems.
• When LED number 8 is on steady, this indicates that the CPU module is sending a drive reverse
command. This is only applicable for RDSI systems.

4.8 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).
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Inputs:
The four analog input signals are able to receive voltage signals from 0 to +10VDC, at an 8-bit resolution. The input impedance is 20K for these inputs. The inputs share a common ground reference, which is shared with the Flex M system ground.
Figure 27. Analog I/O Module Detail View
Figure 28. Analog I/O Module Wiring
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4.8.1 ANALOG I/O MODULE LED OPERATION

When the Flex M system is supplying power to the Analog I/O module, an LED indicates the power and communication status of the Analog I/O module.
Figure 29. Analog I/O Module LED Placement
• OK LED
o Solid indicates module communication with system is good o 3 Blinks indicates read/write error to attached CPU module
Additionally, there are 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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4.9 DIGITAL INPUT MODULE – GEN 1

This section is applicable to the following digital input part number(s):
• 25-02-074-808E (12-24VDC)
• 25-02-074-817E (50-75VDC)
Identifying a GEN1 Digital Input 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 Digital Input module allows the reading of twelve digital signals (12-24VDC or 50-75VDC). Custom DC voltage inputs are available upon request. The DC power is not supplied by the card, so a separate power supply needs to be installed to the power inputs. The rotary switch, which is located on the lower left corner of the board, sets the digital input module number.
Figure 30. GEN1 Digital Input Module Detail View
Figure 31. GEN1 Digital Input Module Wiring
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4.9.1 DIGITAL INPUT MODULE LED OPERATION

When the Flex M system is supplying power to the Digital Input module, an LED indicates the power and communication status of the Relay module.
Figure 32. GEN1 Digital Input Module LED Placement
• OK LED
o Solid indicates module communication with system is good o 3 Blinks indicates read/write error to attached CPU module
Additionally, there are eight LEDs labeled 1 through 8 on the Digital Input module. When the LED is on, this indicates that the module is receiving a signal/input at that input.
• LED1
o Digital Input 1 is active (non-zero)
• LED2
o Digital Input 2 is active (non-zero)
• LED3
o Digital Input 3 is active (non-zero)
• LED4
o Digital Input 4 is active (non-zero)
• LED5
o Digital Input 5 is active (non-zero)
• LED6
o Digital Input 6 is active (non-zero)
• LED7
o Digital Input 7 is active (non-zero)
• LED8
o Digital Input 8 is active (non-zero)
Inputs 9 through 12 do not have a viewable LED.
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4.10 DIGITAL INPUT MODULE – GEN 2

This section is applicable to the following digital input part number(s):
• 198-80104-DNPT1
Identifying a GEN2 Digital Input module:
• The module will contain a label with the part number listed above
• The LED overlay decal will be blue
The Flex M Digital Input module allows the reading of eight digital signals. Each of the digital inputs can be configured for a range of 4-36VDC (Low Range) or 36V-240VAC/DC (High Range) operation for either AC or DC voltages via a manual jumper connection. Refer to Figure 33 for jumper locations and settings.
The input reference voltage is not supplied by the card. Figure 34 shows the wiring for the module. For each input pair, one input is used for the reference and the other input is used for the input to be read.
The rotary switch, located on the lower left corner of the board, sets the digital input module number.
Figure 33. GEN2 Digital Input Module Detail View
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Figure 34. GEN2 Digital Input Module Wiring

4.10.1 DIGITAL INPUT MODULE LED OPERATION

When the Flex M system is supplying power to the Digital Input module, there is an LED that indicates the power and communication status of the Digital Input module.
Figure 35. GEN2 Digital Input Module LED Placement
• OK LED
o Solid indicates module communication with system is good o 3 Blinks indicates read/write error to attached CPU module
Additionally, there are eight LEDs labeled 1 through 8 on the Digital Input module. When the LED is on, this indicates that the module is receiving a signal/input at that input.
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• LED1
• LED2
• LED3
• LED4
• LED5
• LED6
• LED7
• LED8
o Digital Input 1 is active (non-zero)
o Digital Input 2 is active (non-zero)
o Digital Input 3 is active (non-zero)
o Digital Input 4 is active (non-zero)
o Digital Input 5 is active (non-zero)
o Digital Input 6 is active (non-zero)
o Digital Input 7 is active (non-zero)
o Digital Input 8 is active (non-zero)
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5. PROGRAMMING WITH RCP

Using the optional Radio Control Programmer (RCP) software makes programming 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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6. RECEIVER CHANNEL CONFIGURATION SETTINGS

Compliance Statement (Part 15.19)
This portable transmitter with its antenna

6.1 FCC STATEMENTS

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.
complies with FCC’s RF exposure limits for general population/uncontrolled exposure.
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7. GEN 1 RF/CPU CHANNEL DIP SWITCH SETTINGS

Channel
Frequency
SW4
SW5
SW6
SW7
SW8
A
902.30 MHz
DOWN
DOWN
DOWN
UP
DOWN
B
904.10 MHz
UP
DOWN
DOWN
UP
DOWN
C
904.30 MHz
DOWN
UP
DOWN
UP
DOWN
D
905.10 MHz
UP
UP
DOWN
UP
DOWN
E
905.50 MHz
DOWN
DOWN
UP
UP
DOWN
F
905.70 MHz
UP
DOWN
UP
UP
DOWN
G
906.60 MHz
DOWN
UP
UP
UP
DOWN
H
908.70 MHz
UP
UP
UP
UP
DOWN
I
908.90 MHz
DOWN
DOWN
DOWN
DOWN
UP J 909.10 MHz
UP
DOWN
DOWN
DOWN
UP K 910.10 MHz
DOWN
UP
DOWN
DOWN
UP L 910.70 MHz
UP
UP
DOWN
DOWN
UP M 911.00 MHz
DOWN
DOWN
UP
DOWN
UP N 911.20 MHz
UP
DOWN
UP
DOWN
UP O 912.00 MHz
DOWN
UP
UP
DOWN
UP P 914.20 MHz
UP
UP
UP
DOWN
UP Q 914.40 MHz
DOWN
DOWN
DOWN
UP
UP R 914.60 MHz
UP
DOWN
DOWN
UP
UP S 914.80 MHz
DOWN
UP
DOWN
UP
UP T 915.80 MHz
UP
UP
DOWN
UP
UP U 917.40 MHz
DOWN
DOWN
UP
UP
UP V 923.20 MHz
UP
DOWN
UP
UP
UP W 927.00 MHz
DOWN
UP
UP
UP
UP X 927.30 MHz
UP
UP
UP
UP
UP
The channel can be set on the RF/CPU module via the Bank 2 dip switches. The following shows the dip switch settings for each of the channels available for each RF/CPU Module option.
NOTE: See Section 3.9 for instructions on how to remove the CPU/RF module from the din rail and how to remove the PCB from the module housing.
Table 1. CHANNEL DIP SWITCH SETTINGS FOR 900MHZ PART 15 RF/CPU MODULE
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Channel
SW4
SW5
SW6
SW7
SW8
1
UP
UP
UP
UP
UP 2 DOWN
UP
UP
UP
UP 3 UP
DOWN
UP
UP
UP 4 DOWN
DOWN
UP
UP
UP 5 UP
UP
DOWN
UP
UP 6 DOWN
UP
DOWN
UP
UP 7 UP
DOWN
DOWN
UP
UP 8 DOWN
DOWN
DOWN
UP
UP 9 UP
UP
UP
DOWN
UP
10
DOWN
UP
UP
DOWN
UP
11
UP
DOWN
UP
DOWN
UP
12
DOWN
DOWN
UP
DOWN
UP
13
UP
UP
DOWN
DOWN
UP
14
DOWN
UP
DOWN
DOWN
UP
15
UP
DOWN
DOWN
DOWN
UP
16
DOWN
DOWN
DOWN
DOWN
UP
17
UP
UP
UP
UP
DOWN
18
DOWN
UP
UP
UP
DOWN
19
UP
DOWN
UP
UP
DOWN
20
DOWN
DOWN
UP
UP
DOWN
21
UP
UP
DOWN
UP
DOWN
22
DOWN
UP
DOWN
UP
DOWN
23
UP
DOWN
DOWN
UP
DOWN
24
DOWN
DOWN
DOWN
UP
DOWN
25
UP
UP
UP
DOWN
DOWN
26
DOWN
UP
UP
DOWN
DOWN
27
UP
DOWN
UP
DOWN
DOWN
28
DOWN
DOWN
UP
DOWN
DOWN
29
UP
UP
DOWN
DOWN
DOWN
30
DOWN
UP
DOWN
DOWN
DOWN
31
UP
DOWN
DOWN
DOWN
DOWN
32
DOWN
DOWN
DOWN
DOWN
DOWN
Table 2. CHANNEL DIP SWITCH SETTINGS FOR 900MHZ @ 1W RF/CPU MODULE (25-02-074-807E) AND
900MHZ @ 200MW RF/CPU MODULE (25-02-074-815E)
NOTE: Each channel consists of 50+ frequencies within 902 -928 MHz. During operation, all available frequencies will be used by a "Frequency Hopping" protocol.
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Channel
Frequency
SW4
SW5
SW6
SW7
SW8
1
433.000 MHz
DOWN
DOWN
DOWN
DOWN
DOWN
2
433.050 MHz
DOWN
DOWN
DOWN
DOWN
UP 3 433.100 MHz
DOWN
DOWN
DOWN
UP
DOWN
4
433.150 MHz
DOWN
DOWN
DOWN
UP
UP 5 433.200 MHz
DOWN
DOWN
UP
DOWN
DOWN
6
433.250 MHz
DOWN
DOWN
UP
DOWN
UP 7 433.300 MHz
DOWN
DOWN
UP
UP
DOWN
8
433.350 MHz
DOWN
DOWN
UP
UP
UP 9 433.400 MHz
DOWN
UP
DOWN
DOWN
DOWN
10
433.450 MHz
DOWN
UP
DOWN
DOWN
UP
11
433.500 MHz
DOWN
UP
DOWN
UP
DOWN
12
433.550 MHz
DOWN
UP
DOWN
UP
UP
13
433.600 MHz
DOWN
UP
UP
DOWN
DOWN
14
433.650 MHz
DOWN
UP
UP
DOWN
UP
15
433.700 MHz
DOWN
UP
UP
UP
DOWN
16
433.750 MHz
DOWN
UP
UP
UP
UP
17
433.800 MHz
UP
DOWN
DOWN
DOWN
DOWN
18
433.850 MHz
UP
DOWN
DOWN
DOWN
UP
19
433.900 MHz
UP
DOWN
DOWN
UP
DOWN
20
433.950 MHz
UP
DOWN
DOWN
UP
UP
21
434.000 MHz
UP
DOWN
UP
DOWN
DOWN
22
434.050 MHz
UP
DOWN
UP
DOWN
UP
23
434.100 MHz
UP
DOWN
UP
UP
DOWN
24
434.150 MHz
UP
DOWN
UP
UP
UP
25
434.200 MHz
UP
UP
DOWN
DOWN
DOWN
26
434.250 MHz
UP
UP
DOWN
DOWN
UP
27
434.300 MHz
UP
UP
DOWN
UP
DOWN
28
434.350
UP
UP
DOWN
UP
UP
29
434.400
UP
UP
UP
DOWN
DOWN
30
434.450
UP
UP
UP
DOWN
UP
31
434.500
UP
UP
UP
UP
DOWN
32
434.550
UP
UP
UP
UP
UP
Table 3. CHANNEL DIP SWITCH SETTINGS FOR 433MHZ PART 15
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Channel
SW4
SW5
SW6
SW7
SW8
1
DOWN
DOWN
DOWN
DOWN
DOWN
2
UP
DOWN
DOWN
DOWN
DOWN
3
DOWN
UP
DOWN
DOWN
DOWN
4
UP
UP
DOWN
DOWN
DOWN
5
DOWN
DOWN
UP
DOWN
DOWN
6
UP
DOWN
UP
DOWN
DOWN
7
DOWN
UP
UP
DOWN
DOWN
8
UP
UP
UP
DOWN
DOWN
9
DOWN
DOWN
DOWN
UP
DOWN
10
UP
DOWN
DOWN
UP
DOWN
11
DOWN
UP
DOWN
UP
DOWN
12
UP
UP
DOWN
UP
DOWN
13
DOWN
DOWN
UP
UP
DOWN
14
UP
DOWN
UP
UP
DOWN
15
DOWN
UP
UP
UP
DOWN
16
UP
UP
UP
UP
DOWN
17
DOWN
DOWN
DOWN
DOWN
UP
18
UP
DOWN
DOWN
DOWN
UP
19
DOWN
UP
DOWN
DOWN
UP
20
UP
UP
DOWN
DOWN
UP
21
DOWN
DOWN
UP
DOWN
UP
22
UP
DOWN
UP
DOWN
UP
23
DOWN
UP
UP
DOWN
UP
24
UP
UP
UP
DOWN
UP
25
DOWN
DOWN
DOWN
UP
UP
26
UP
DOWN
DOWN
UP
UP
27
DOWN
UP
DOWN
UP
UP
28
UP
UP
DOWN
UP
UP
29
DOWN
DOWN
UP
UP
UP
30
UP
DOWN
UP
UP
UP
31
DOWN
UP
UP
UP
UP
32
UP
UP
UP
UP
UP
Table 4. CHANNEL DIP SWITCH SETTINGS FOR 2.4GHZ RF/CPU MODULES
NOTE: Each channel consists of 43+ frequencies within the 2.4GHz range. During operation, all available frequencies will be used by a "Frequency Hopping" protocol.
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Channel
Frequency
SW1
SW2
SW3
SW4
SW5
AK01
439.8
UP
DOWN
DOWN
DOWN
DOWN
AK02
439.6
DOWN
UP
DOWN
DOWN
DOWN
AK03
439.4
UP
UP
DOWN
DOWN
DOWN
AK04
439.2
DOWN
DOWN
UP
DOWN
DOWN
AK05
439.0
UP
DOWN
UP
DOWN
DOWN
AK06
438.8
DOWN
UP
UP
DOWN
DOWN
AK07
438.6
UP
UP
UP
DOWN
DOWN
AK08
438.4
DOWN
DOWN
DOWN
UP
DOWN
AK09
438.2
UP
DOWN
DOWN
UP
DOWN
AK10
438.0
DOWN
UP
DOWN
UP
DOWN
AK11
437.8
UP
UP
DOWN
UP
DOWN
AK12
437.6
DOWN
DOWN
UP
UP
DOWN
AK13
437.4
UP
DOWN
UP
UP
DOWN
AK14
437.2
DOWN
UP
UP
UP
DOWN
AK15
437.0
UP
UP
UP
UP
DOWN
AK16
436.8
DOWN
DOWN
DOWN
DOWN
UP
AK17
436.6
UP
DOWN
DOWN
DOWN
UP
AK18
436.4
DOWN
UP
DOWN
DOWN
UP
AK19
436.2
UP
UP
DOWN
DOWN
UP
AK20
436.0
DOWN
DOWN
UP
DOWN
UP
AKA00
433.125
UP
DOWN
UP
DOWN
UP
AKA01
433.325
DOWN
UP
UP
DOWN
UP
AKA02
433.525
UP
UP
UP
DOWN
UP
AKA03
433.725
DOWN
DOWN
DOWN
UP
UP
AKA04
433.925
UP
DOWN
DOWN
UP
UP
AKA05
434.125
DOWN
UP
DOWN
UP
UP
AKA06
434.325
UP
UP
DOWN
UP
UP
AKA07
434.525
DOWN
DOWN
UP
UP
UP
AKA08
434.725
UP
DOWN
UP
UP
UP
Table 5. CHANNEL DIP SWITCH SETTINGS FOR 433MHZ (TELEMOTIVE CHANNEL SET) RF/CPU MODULE
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8. CHANNEL SETS

Channel
Frequency
01
433.000 MHz
02*
433.050 MHz
03*
433.100 MHz
04*
433.150 MHz
05*
433.200 MHz
06*
433.250 MHz
07*
433.300 MHz
08*
433.350 MHz
09*
433.400 MHz
10*
433.450 MHz
11*
433.500 MHz
12*
433.550 MHz
13*
433.600 MHz
14*
433.650 MHz
15*
433.700 MHz
16*
433.750 MHz
17*
433.800 MHz
18*
433.850 MHz
19*
433.900 MHz
20*
433.950 MHz
21*
434.000 MHz
22*
434.050 MHz
23*
434.100 MHz
24*
434.150 MHz
25*
434.200 MHz
26*
434.250 MHz
27*
434.300 MHz
28*
434.350 MHz
29*
434.400 MHz
30*
434.450 MHz
31*
434.500 MHz
32*
434.550 MHz

8.1 433MHZ CHANNEL SET

NOTE: Channels marked with * are approved for use in Australia.
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8.2 419MHZ CHANNEL SET

Channel
Frequency
Channel
Frequency
1*
418.950
44
417.500
2*
418.975
45
417.550
3*
419.000
46
417.600
4*
419.025
47
417.650
5*
419.050
48
417.700
6*
419.075
49
417.750
7*
419.100
50
417.800
8*
419.125
51
417.850
9*
419.150
52
417.900
10*
419.175
53
417.950
11*
419.200
54
418.000
12*
419.250
55
418.050
13*
419.275
56
418.100
14
416.000
57
418.150
15
416.050
58
418.200
16
416.100
59
418.250
17
416.150
60
418.300
18
416.200
61
418.350
19
416.250
62
418.400
20
416.300
63
418.450
21
416.350
64
418.500
22
416.400
65
418.550
23
416.450
66
418.600
24
416.500
67
418.650
25
416.550
68
418.700
26
416.600
69
418.750
27
416.650
70
418.800
28
416.700
71
418.850
29
416.750
72
418.900
30
416.800
73
419.350
31
416.850
74
419.400
32
416.900
75
419.450
33
416.950
76
419.500
34
417.000
77
419.550
35
417.050
78
419.600
36
417.100
79
419.650
37
417.150
80
419.700
38
417.200
81
419.750
39
417.250
82
419.800
40
417.300
83
419.850
41
417.350
84
419.900
42
417.400
85
419.950
43
417.450
NOTE: Channels marked with * are approved for use in China.
May 2019
Page 45 of 50
Page 46

8.3 2.4 GHZ: FHSS

Channel hop sequences are designated between 1 and 32. The frequency range is between 2402-2478 MHz. The frequency hopping protocol does not use one particular frequency to transmit a message; messages are transmitted over multiple frequencies in a predefined sequence or channel set. In doing so, this protocol is able to compensate for interference that may be present on a single frequency by sending the message across multiple frequencies.
This receiver is available with optional licensed frequencies per customer request. If utilizing a licensed frequency, please refer to the factory application documentation that shipped with the receiver, or contact the factory for licensed frequency details.
May 2019
Page 46 of 50
Page 47

9. TROUBLESHOOTING

WARNING

THE OPERATOR SHOULD NOT ATTEMPT TO REPAIR ANY RADIO CONTROLLER. IF ANY PRODUCT PERFORMANCE OR SAFETY CONCERNS ARE OBSERVED, THE EQUIPMENT SHOULD IMMEDIATELY BE TAKEN OUT OF SERVICE AND BE REPORTED TO THE SUPERVISOR. DAMAGED AND INOPERABLE RADIO CONTROLLER EQUIPMENT SHOULD BE RETURNED TO MAGNETEK FOR EVALUATION AND REPAIR. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
May 2019
Page 47 of 50
Page 48

9.1 TROUBLESHOOTING TABLE

Supplied voltage is out of the acceptable range.
Ensure the input voltage is within the range of the installed power supply module.
contact the factory for support.
WDG/Online LED on
le is blinking 2
MSG LED does not blink.
WDG/Online LED on
g 1
a signal strength.
WDG/Online LED on
an erratic signal.
WDG/Online LED on
s blinking 3
modules.
Inspect the antenna on the receiver for
when operating the equipment at all times.
Move the transmitter and receiver closer together.
Install the receiver antenna where it is within sight of the equipment operator.
on
Inspect the antenna on the receiver for
for installation.
Problems Possible Reasons Suggestions
Receiver will not
turn on, +5VDC
CPU/RELAY
LEDs on Power
Supply Module
do not light up
Receiver will not
respond to the
transmitter
Internal fuse has blown on power supply module.
Internal Power supply on PCB has a problem.
CPU/RF modu times (communication loss with transmitter), and RF
CPU/RF module is blinkin time (normal operating WDG), RF MSG LED does not blink and RF Signal strength LEDs are indicating
CPU/RF module is blinking 1 time (normal operating WDG), RF MSG LED does not blink and RF Signal strength LEDs are indicating
If it is a Rev 2 module, replace fuse. If fuse fails again, system troubleshooting is required to determine cause. Otherwise
Contact the factory for repair.
Verify that the transmitter is still operating. Ensure the receiver and transmitter unit are within operating range.
Verify the receiver and transmitter unit have the same access code.
Verify that the receiver and transmitter are set to the same channel.
CPU/RF module i times, read/write error with
The antenna on the receiver is missing, damaged, or improperly installed.
Transmitter and receiver are
Receiver
on the edge of the transmission range.
responds to the
transmitter
intermittently
The antenna and/or cable the receiver is damaged, or improperly installed.
Verify the modules are securely connected on the DIN rail. If the problem persists, contact the factory for repair.
damage.
Ensure the antenna is visible to the operator
damage and try to place the antenna in a location that is visible to the equipment operator at all times. Refer to Section
3.4
Page 48 of 50
May 2019
Page 49
Problems Possible Reasons Suggestions
Drive Connected
respond
The transmitter powered TEST due to inactivity.
Extend the inactivity timeout setting for the transmitter.
The transmitter powered TEST due to low batteries.
The RF/Message LED stops
MLC Relay turning off.
The RF/Message LED
that is driving a contactor.
the watchdog LED is blinking
Ensure that the transmitter is properly
transmitter.
The serial data timeout error
LED is lit.
Digital Input
input
Contact state is selectable
closed.
to Serial
Communication
Card does not
The MLC
(Master) Relay
turns off during
normal operation
LED #6 is lit up, module is wired in test mode (drive connection is being simulated).
blinking for more than 3 seconds, followed by the
stopped and the MLC Relay turned off together within 1 sec, possibly when engaging or disengaging another relay
The MLC has turned off and
the amber LED 6 times.
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
Ensure wiring of the drive(s) to the Serial communication card is correct.
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.
communicating with the receiver and that the START has been activated on the
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.
Module not
detecting an
Relay contacts
opposite from
what is expected
Input voltage is greater than 36V and internal selector is set to LOW band.
for relays K1 and K2, allowing active state to have contacts either open or
Verify input jumper is set to HIGH band for voltages over 36V
Ensure jumpers for relays K1 and K2 are installed in the desired positions.
Page 49 of 50
May 2019
Page 50

10. EU DECLARATION OF CONFORMITY

May 2019
Page 50 of 50
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