Magnetek inteleSmart2 Receiver Pre-Engineered Owner's manual

inteleSmart2 RECEIVER

Pre-Engineered

AC/DC Relay Receiver

Part Number: 198-80102-0003 R03

April 2019

Pre-Engineered inteleSmart2 Instruction Manual

April 2019

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SERVICE INFORMATION

Your New Radio Remote Control System

Thank you for your purchase of Magnetek’s inteleSmart2 Receiver Radio Remote Equipment Control.

Magnetek has set a whole new standard in radio-remote performance, dependability, and value with this

line of modular transmitters.

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: mhcustomerservice@magnetek.com

Fax Numbers:

Main: 800-298-3503

Sales: 262-783-3510

Service: 262-783-3508

Canada Service Information:

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)

EU Market Contact:

Brian Preston

Magnetek (UK) Ltd.

Unit 3 Bedford Business Centre

Mile Road

Bedford, MK42 9TW UK

Phone: +44-1234-349191

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.

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TABLE OF CONTENTS

1. PREFACE AND SAFETY ................................................................................................................... 6

1.1 PRODUCT MANUAL SAFETY INFORMATION ........................................................................... 6

1.2 PRODUCT WARRANTY INFORMATION .................................................................................... 6

2. CRITICAL INSTALLATION CONSIDERATIONS ............................................................................... 8

2.1 GENERAL ..................................................................................................................................... 8

2.2 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED EQUIPMENT ....................... 8

2.3 SAFEY INFORMATION & RECOMMENDED TRAINING FOR OPERATORS ............................ 8

2.4 PRE-OPERATION TEST ............................................................................................................ 10

2.5 CRANE-SPECIFIC DEVICE WARNINGS .................................................................................. 10

3. INTELESMART2 INSTALLATION ................................................................................................... 11

3.1 PRE-INSTALLATION .................................................................................................................. 11

3.2 RECEIVER UNIT MOUNTING LOCATION CONSIDERATIONS ............................................... 11

3.3 ANTENNA MOUNTING CONSIDERATIONS ............................................................................. 11

3.4 LINE INPUT CONSIDERATIONS ............................................................................................... 12

3.5 WIRING CONSIDERATION ........................................................................................................ 12

3.6 RECEIVER/EQUIPMENT INTERFACE CONSIDERATIONS .................................................... 12

3.7 RECEIVER UNIT ENCLOSURE MOUNTING ............................................................................ 13

3.8 RECEIVER INSTALLATION ....................................................................................................... 13

3.9 MECHANICAL DRAWINGS ........................................................................................................ 14

4. WIRING ............................................................................................................................................ 16

4.1 ALARMS AND HORNS ............................................................................................................... 16

4.2 POWER ....................................................................................................................................... 16

4.2.1 DC Power ............................................................................................................................ 16

4.2.2 AC Power ............................................................................................................................ 16

4.3 COMMONS ................................................................................................................................. 17

4.4 POWER OR HOT ROUTING ...................................................................................................... 17

4.5 MACHINE STOP (MC) RELAYS................................................................................................. 17

4.6 WIRING DIAGRAMS ................................................................................................................... 18

4.6.1 Wiring Isolation Options ...................................................................................................... 20

4.7 CONNECTING OUTPUTS TO DRIVES ..................................................................................... 20

4.8 ANALOG INPUT ......................................................................................................................... 20

4.9 DIGITAL INPUTS ........................................................................................................................ 21

4.10 EXPANSION MODULES ............................................................................................................ 21

5. NORMAL OPERATION .................................................................................................................... 22

5.1 INITIALIZATION .......................................................................................................................... 23

6. INTELESMART2 EXPANSION MODULE TYPES ........................................................................... 23

6.1 RELAY EXPANSION MODULE .................................................................................................. 23

7. Pre-Engineered Wiring diagrams ..................................................................................................... 25

7.1 Relay Sequencing ....................................................................................................................... 25

7.2 Alarm After ESTOP ..................................................................................................................... 25

7.3 Single-Speed Transmitter Wiring ................................................................................................ 25

7.4 2-Speed and 3-Speed telePendant operation ............................................................................. 25

7.5 Transfer Switch ........................................................................................................................... 26

7.6 Pre-Engineered Transmitter Layout ............................................................................................ 26

7.7 Legend ........................................................................................................................................ 28

8. 12 Output Configurations ................................................................................................................. 29

8.1 1-SPEED STANDARD CONFIGURATION HOIST, TROLLEY AND BRIDGE........................... 29

8.1.1 Transmitter/Receiver Setup ................................................................................................ 30

8.2 2-SPEED STANDARD CONFIGURATION HOIST, TROLLEY AND BRIDGE........................... 31

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8.2.1 Transmitter/Receiver Setup ................................................................................................ 32

8.3 2-SPEED with DIRECTIONAL CONTROLS: ALL MOTIONS .................................................... 33

8.3.1 Transmitter/Receiver Setup ................................................................................................ 34

8.4 2-SPEED, 2-WINDINGS: ALL MOTIONS .................................................................................. 35

8.4.1 Transmitter/Receiver Setup ................................................................................................ 36

8.5 2-SPEED ACCO CONTROLS: ALL MOTIONS .......................................................................... 37

8.5.1 Transmitter/Receiver Setup ................................................................................................ 38

8.6 P&H: 2-SPEED, 2-WINDINGS for HOIST and TROLLEY; STANDARD BRIDGE ..................... 39

8.6.1 Transmitter/Receiver Setup ................................................................................................ 40

8.7 P&H: 2-SPEED, 2-WINDINGS for HOIST; STANDARD TROLLEY and BRIDGE ..................... 41

8.7.1 Transmitter/Receiver Setup ................................................................................................ 42

8.8 DEMAG: 2-SPEED, 2-WINDINGS for HOIST; STANDARD TROLLEY and BRIDGE .............. 43

8.8.1 Transmitter/Receiver Setup ................................................................................................ 44

8.9 STANDARD 2-SPEED 4 MOTOR SYSTEM ............................................................................... 45

8.9.1 Transmitter/Receiver Setup ................................................................................................ 46

8.10 STANDARD 2-SPEED 4 & 5 MOTOR SYSTEM using SELECT ............................................... 47

8.10.1 Transmitter/Receiver Setup ................................................................................................ 48

8.11 STANDARD 3-SPEED 2 MOTOR SYSTEM (Using a 3-Speed Transmitter) ............................. 49

8.11.1 Transmitter/Receiver Setup ................................................................................................ 50

9. 24 Output Configurations ................................................................................................................. 51

9.1 3-SPEED STANDARD CONFIGURATION HOIST, AUX HOIST, TROLLEY, AUX TROLLEY

and BRIDGE ............................................................................................................................................ 51

9.1.1 Transmitter/Receiver Setup ................................................................................................ 52

9.2 3-SPEED STANDARD CONFIGURATION HOIST, TROLLEY and BRIDGE with 6

INDEPENDENT AUXILIARIES ............................................................................................................... 53

9.2.1 Transmitter/Receiver Setup ................................................................................................ 54

9.3 3-SPEED STANDARD CONFIGURATION HOIST, AUX HOIST, TROLLEY, AUX TROLLEY

and BRIDGE with SELECT LOGIC ......................................................................................................... 55

9.3.1 Transmitter/Receiver Setup ................................................................................................ 56

9.4 2-SPEED DIRECTIONAL CONTROLS ALL MOTIONS ............................................................. 57

9.4.1 Transmitter/Receiver Setup ................................................................................................ 58

9.5 3-SPEED 2-WINDINGS: ALL MOTIONS .................................................................................... 59

9.5.1 Transmitter/Receiver Setup ................................................................................................ 60

9.6 2-SPEED ACCO CONTROLS: ALL MOTIONS .......................................................................... 61

9.6.1 Transmitter/Receiver Setup ................................................................................................ 62

9.7 DEMAG: 2-SPEED, 2-WINDINGS for HOIST and AUX HOIST; STANDARD 3-SPEED for

TROLLEY, AUX TROLLEY and BRIDGE ............................................................................................... 63

9.7.1 Transmitter/Receiver Setup ................................................................................................ 64

9.8 P & H: 2-SPEED, 2-WINDINGS for HOIST and AUX HOIST; STANDARD 3-SPEED for

TROLLEY, AUX TROLLEY and BRIDGE ............................................................................................... 65

9.8.1 Transmitter/Receiver Setup ................................................................................................ 66

9.9 P & H: 2-SPEED, 2-WINDINGS for HOIST, AUX HOIST, TROLLEY, and AUX TROLLEY;

STANDARD 3-SPEED BRIDGE ............................................................................................................. 67

9.9.1 Transmitter/Receiver Setup ................................................................................................ 68

9.10 P & H: 2-SPEED, 2-WINDINGS for HOIST, TROLLEY, and AUX TROLLEY; with CREEP

SPEED AUX HOIST; STANDARD 3-SPEED for BRIDGE ..................................................................... 69

9.10.1 Transmitter/Receiver Setup ................................................................................................ 70

9.11 P & H: 2-SPEED, 2-WINDINGS for HOIST; with CREEP SPEED AUX HOIST; STANDARD 3-

SPEED for TROLLEY, AUX TROLLEY, AND BRIDGE .......................................................................... 71

9.11.1 Transmitter/Receiver Setup ................................................................................................ 72

9.12 STANDARD 5-SPEED for 5 SPEED LEVER SWITCH TRANSMITTER.................................... 73

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9.12.1 Transmitter/Receiver Setup ................................................................................................ 74

10. PROGRAMMING WITH RCP .......................................................................................................... 75

10.1 Receiver Programming Overview ............................................................................................... 75

10.2 ACCESS CODES ........................................................................................................................ 75

10.2.1 CHANGING ACCESS CODES ........................................................................................... 75

10.3 CONNECTING THE INTELESMART2 TO A COMPUTER ........................................................ 76

10.4 Install the RCP Software ............................................................................................................. 76

10.5 Getting Started WITH RCP ......................................................................................................... 77

10.5.1 Run the RCP Software ........................................................................................................ 77

10.5.2 Click on New Project or Open Project ................................................................................. 77

10.5.3 inteleSmart2 Configuration Page ........................................................................................ 79

10.5.4 Programming Page ............................................................................................................. 82

10.5.5 FDP Page ............................................................................................................................ 82

11. PRE-ENGINEERED RECEIVER PROGRAMMING ........................................................................ 85

11.1 Programming Frequency and Access Code ............................................................................... 85

11.2 Configuring a Receiver ................................................................................................................ 86

11.3 Custom Output Mapping ............................................................................................................. 89

11.4 Saving, Downloading, And Reading The Programs And Other RCP Software Functions ......... 90

12. RECEIVER CHANNEL CONFIGURATION SETTINGS .................................................................. 92

12.1 FCC STATEMENTS .................................................................................................................... 92

12.2 433MHz CHANNEL SET ............................................................................................................. 93

12.3 433MHz Telemotive Legacy Channel Set ................................................................................... 94

12.4 900MHz CHANNEL SET ............................................................................................................. 95

12.5 419MHz CHANNEL SET ............................................................................................................. 96

12.6 2.4 GHz: FHSS............................................................................................................................ 97

13. TROUBLESHOOTING ..................................................................................................................... 97

13.1 TROUBLESHOOTING TABLE .................................................................................................... 98

13.2 RECEIVER SPECIFICATIONS ................................................................................................. 101

14. DECLARATION OF CONFORMITY .............................................................................................. 102

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1. PREFACE AND SAFETY

but not limited to, this manual. This manual is intended for the sole use of the persons 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.

1.1 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.

1.2 PRODUCT WARRANTY INFORMATION

Magnetek, hereafter referred to as Company, assumes no responsibility for improper programming or

installation of a device (such as a drive or radio) by untrained personnel. A device should only be

programmed or installed by a trained technician who has read and understands the contents of the

relevant manual(s). Improper programming or installation of a device can lead to unexpected,

undesirable, or unsafe operation or performance of the device. This may result in damage to equipment

or personal injury. Company shall not be liable for economic loss, property damage, or other

consequential damages or physical injury sustained by the purchaser or by any third party as a result of

such programming or installation. Company neither assumes nor authorizes any other person to assume

for Company any other liability in connection with the sale or use of this product.

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.

FOLLOW YOUR LOCAL LOCKOUT TAGOUT PROCEDURE BEFORE MAINTAINING ANY REMOTE

CONTROLLED EQUIPMENT. ALWAYS REMOVE ALL ELECTRICAL POWER FROM THE EQUIPMENT BEFORE

ATTEMPTING ANY INSTALLATION PROCEDURES. DE-ENERGIZE AND TAGOUT ALL SOURCES OF

ELECTRICAL POWER BEFORE TOUCH-TESTING ANY EQUIPMENT. FAILURE TO FOLLOW THIS WARNING

COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

AFTER INSTALLATION BE SURE TO VERIFY THAT THE TRANSMITTER IS NOT INTERFERING WITH OTHER

EQUIPMENT IN THE AREA. ALSO VERIFY THAT OTHER EQUIPMENT IS NOT INTERFERING WITH THE

TRANSMITTER AND ITS ASSOCIATED EQUIPMENT. FAILURE TO FOLLOW THESE WARNINGS COULD

RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

2.1 GENERAL

Radio controlled equipment operates in several directions. Quite frequently, the equipment is operated in areas

where people are working in close proximity to the equipment. The operator must exercise extreme caution at all

times. Workers must constantly be alert to avoid accidents. The following recommendations have been included to

indicate how careful and thoughtful actions may prevent injuries, damage to equipment, or even save a life.

2.2 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED

EQUIPMENT

Only properly trained persons designated by management should be permitted to operate radio controlled equipment.

Radio controlled 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.

2.3 SAFEY 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

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• have the ability to judge distance of moving objects

• know how to properly test prior to operation

• be trained in the safe operation of the radio transmitter as it pertains to the equipment being operated

• have knowledge of the use of equipment warning lights and alarms

• have knowledge of the proper storage space for a radio control transmitter when not in use

• be trained in transferring a radio control transmitter to another person

• be trained how and when to report unsafe or unusual operating conditions

• test the transmitter emergency stop and all warning devices prior to operation; testing should be done on

each shift, without a load

• be thoroughly trained and knowledgeable in proper and safe operation of the equipment that utilizes the

radio control

• know how to keep the operator and other people clear of hazardous areas

• know and follow the local lockout and tagout procedures when servicing radio controlled equipment

• know and follow all applicable operating and maintenance manuals, safety procedures, regulatory

requirements, and industry standards and codes

The operator shall not:

• operate the equipment if the direction of travel or function engaged does not agree with what is indicated on

the controller

• operate any damaged or malfunctioning equipment

• change any settings or controls without authorization and proper training

• remove or obscure any warning or safety labels or tags

• leave power on the radio controlled equipment when the equipment is not in operation

• operate any equipment using a damaged controller because the unit may be unsafe

• operate manual motions with other than manual power

• operate radio controlled equipment when low battery indicator is on

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.

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2.4 PRE-OPERATION TEST

At the start of each work shift, or when a new operator takes control of the equipment, operators should do,

as a minimum, the following steps before making lifts with any equipment:

Test all warning devices.

Test all functions.

Test the transmitter machine stop.

2.5 CRANE-SPECIFIC DEVICE WARNINGS

WARNING

ALL EQUIPMENT MUST HAVE A MAINLINE CONTACTOR INSTALLED AND ALL TRACKED CRANES, HOISTS,

LIFTING DEVICES AND SIMILAR EQUIPMENT MUST HAVE A BRAKE INSTALLED. FAILURE TO FOLLOW THIS

WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

AN AUDIBLE AND/OR VISUAL WARNING MEANS MUST BE PROVIDED ON ALL REMOTE CONTROLLED

EQUIPMENT AS REQUIRED BY CODE, REGULATION, OR INDUSTRY STANDARD. THESE AUDIBLE AND/OR

VISUAL WARNING DEVICES MUST MEET ALL GOVERNMENTAL REQUIREMENTS. FAILURE TO FOLLOW

THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

THE DIRECT OUTPUTS OF THIS PRODUCT ARE NOT DESIGNED TO INTERFACE DIRECTLY TO TWO STATE

SAFETY CRITICAL MAINTAINED FUNCTIONS, I.E., MAGNETS, VACUUM LIFTS, PUMPS, EMERGENCY

EQUIPMENT, ETC. A MECHANICALLY LOCKING INTERMEDIATE RELAY SYSTEM WITH SEPARATE POWER

CONSIDERATIONS MUST BE PROVIDED. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS

INJURY OR DEATH OR DAMAGE TO EQUIPMENT.

Cranes, hoists, lifting devices and other material handling equipment can be large, and operate at high speeds.

The operator should:

• continuously watch and monitor status of lifted loads

• know and follow cable and hook inspection procedures

The operator shall not:

• lift or move more than the rated load

• use the crane, hoist or lifting device to lift, support or transport people

• lift or carry any loads over people

• operate the crane, hoist or lifting device unless all persons, including the operator, are and remain clear of

the supported load and any potential pinch points

• operate a crane, hoist or lifting device when the device is not centered over the load

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• operate a crane, hoist or lifting device if the chain or wire rope is not seated properly in the sprockets, drum

or sheave

• leave any load unattended while lifted

3. INTELESMART2 INSTALLATION

WARNING

BEFORE OPERATING THE RECEIVER FAMILIARIZE YOURSELF WITH ALL SAFETY INFORMATION IN

THIS MANUAL, APPROPRIATE MANUAL SUPPLEMENTS AND ANY OTHER LOCAL, STATE, OR FEDERAL

RULES OR REGULATIONS ALREADY IN EXISTENCE. FAILURE TO FOLLOW THIS WARNING COULD

RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

3.1 PRE-INSTALLATION

1. Transmitter and receiver access code, channel, and project ID must match before the system will

communicate.

2. 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.

3.2 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 receiver enclosure is approximately 20cm (8 in) wide by 30cm (12 in) high by 13cm (5.1 in) deep.

The mounting surface must be smooth and continuous. Mounting the cabinet on uneven surfaces could

cause warping or stress internal components.

If possible, avoid installing receiver unit to a surface where high vibration or shock is present. If this

cannot be avoided, use appropriate shock mounts.

3.3 ANTENNA MOUNTING CONSIDERATIONS

It is best to mount the antenna so that it is visible to the operator. For overhead crane installations, 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 perpendicular to the operator. Always try to avoid power

sources, motors, drives, brakes, etc., when installing the antenna.

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For installations where the receiver and antenna are not mounted overhead of the operator, it is

recommended that the antenna be mounted in a vertical orientation from the operator. The antenna

should be visible to the operator, nor should it be surrounded metal or enclosed. Following these

guidelines will yield optimal performance.

If necessary, Magnetek offers an external antenna kit.

3.4 LINE INPUT CONSIDERATIONS

WARNING

THE UNIT MUST BE WIRED TO THE CORRECT VOLTAGE, AND BE CONNECTED TO THE CORRECT

TERMINAL AS REQUIRED BY THE ACTUAL LINE VOLTAGE. FAILURE TO FOLLOW THIS WARNING

COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.

Refer to Section 4.2 for information on how to configure the unit’s input power.

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.

3.5 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 or 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 4.4 IN-LBS (.5 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.

3.6 RECEIVER/EQUIPMENT INTERFACE CONSIDERATIONS

All output relay contacts are rated for 10 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.

Relay outputs K1-K11 are normally open, single pole single throw (SPST) relays. Relay output K12 is a

normally open, dual pole single throw (DPST) relay. Relay outputs K13-K14 are Form C “flip-flop” relays

(flip-flop relays contain both normally open and normally closed outputs). Since a relay closure is only

active while the transmitter unit key is pressed and held, devices such as lights or lifting magnets must

use a mechanical auxiliary latching relay.

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3.7 RECEIVER UNIT ENCLOSURE MOUNTING

When mounting the receiver, make sure to allow room for the door to swing open. Mount the receiver unit

cabinet securely to the mounting surface. Actual cabinet mounting dimensions are shown in Section 3.9.

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.

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 inteleSmart2 near unshielded

variable frequency drives, Magnetek typically recommends that the inteleSmart2 and all antenna

cable routing be mounted a minimum of 61cm (24 in) from all unshielded variable frequency drives

and cables.

3. Allow adequate room for mounting the receiver. Be sure to allow a minimum of 12.7cm (5 in) 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 such that the external antenna connector is pointing straight up and the connections come

out the bottom of the unit. Placement of the antenna needs to be in a location such that there is line of

sight between the antenna and the transmitter. Refer to Section 3.3 for additional antenna mounting

considerations.

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 supply power to the inteleSmart2 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 10 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. Enclosure mounting dimensions and mounting can be found in

Figure 1.

10. Mount the receiver. Refer to Section 3.9 for further information regarding mounting.

11. Wire the unit using the electrical drawings shown in Section 8 or 9.

12. Wire the power input for the input power type as described in Section 4.2.

13. Wiring of the system should now be complete. Install antenna.

14. If there are any problems, refer to Section 13.

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3.9 MECHANICAL DRAWINGS

The receiver housing provides four mounting holes. The mounting hardware should consist of M5 (#10-

24) combo drive round head screws that are 40mm (1.5 in) in length, four M5 (#10) lock washers, and

four M5 (#10-24) hex nuts to mount. Lock washers should be used in front of hex nuts.

7,87"

200mm

7.09"

180mm

11.02"

279.9mm

11.81"

300mm

.30" DIA.

7.5 mm

Hole 4 places

Figure 1: Housing Mounting

NOTE: Figure 1 is not to scale.

Pre-Engineered inteleSmart2 Instruction Manual

April 2019

Page 15 of 102

Figure 2 shows the placement of the major components used within the receiver.

Figure 2: Main Board Component Placement

J8 J7 J27 F1

TRANSFORMER

J25

J1

F2

J29

K1

K2

K3

K4

K5

K6

K7

K8

K9

K10

K11

K12

K13

K14

K15

K16

J23

USB

IR

LEDs

RF

DIGITAL

INPUTS

EXPANSION

MODULE 1

EXPANSION

MODULE 1

EXPANSION

MODULE 2

J3

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4. WIRING

4.1 ALARMS AND HORNS

Make sure that the installation includes the proper alarms, horns, indicator lights, and their associated

controls as required by local and governmental regulations.

4.2 POWER

The inteleSmart2 can be powered from 24/42/48VAC, 48/115/230VAC, or 6-36VDC. The unit needs to be

configured based upon the type of input power that is being used.

4.2.1 DC Power

To power the unit with 6-36VDC, the input power needs to be connected to J29. Pin 1 is VCC and pin 2 is

ground.

.

4.2.2 AC Power

There are two different AC power transformers that can be populated within the receiver. One transformer

supports 48/115/230VAC, 50/60Hz and another transformer supports 24/42/48VAC, 50/60Hz. Input

voltage ranges are configured by changing the position of the wire jumper in J7. See Table 1 for the

jumper settings for the 48/115/230VAC power supply.

Voltage Range

Position 1

Position 2

48VAC

36-60VAC

3

4

115VAC

85-150VAC (Default)

2

4

230VAC

190-265VAC

1

4

Table 1: 48/115/230VAC Transformer Input Power Wiring

Table 2 has the jumper settings for when the 24/42/48VAC power supply is used.

Voltage Range

Position 1

Position 2

24VAC

18-36VAC (Default)

3

4

42VAC

36-48VAC

2

4

48VAC

36-60VAC

1

4

Table 2: 24/42/48VAC Input Power Wiring

NOTE: These jumper settings apply whether the AC signal is operating at 50Hz or 60Hz.

1

J29

Pre-Engineered inteleSmart2 Instruction Manual

April 2019

Page 17 of 102

The input power then needs to be connected to J27. Pin 3 is line, pin 2 is neutral, and pin 1 is earth

ground.

4.3 COMMONS

Each receiver relay output (normally open or normally closed) is independent (floating), both input and

output. Relay commons (inputs/hot) are not wired together on the receiver board, nor are they connected

to the input power. Relay common wiring must be provided by the user; this is to give total flexibility in

wiring. Different motors and/or functions can use different phases or independent power sources

(including DC voltage). Refer to Section 4.6.1 for recommendations on methods to add additional

isolation.

4.4 POWER OR HOT ROUTING

The diagrams in Section 4.6 show independent power “HOT” routed to each relay. An alternate way of

routing power is to route all power to each function from the Machine Stop (MC) (K15 and K16) relays.

This wiring can only be used if the total current does not exceed the Machine Stop relay ratings.

4.5 MACHINE STOP (MC) RELAYS

The inteleSmart2 contains two relays that can be used as redundant machine stop (mainline) relays.

These relays (K15 and K16) have both normally open and normally closed contacts. This is to give

maximum flexibility when wiring these relays. While it is not necessary to use the redundancy provided by

these relay outputs, Magnetek highly recommends that both of these be utilized.

When wiring the machine stop relays and both relays are being used, Magnetek recommends wiring the

relays in series with one another. The example in Figure 3 shows wiring the normally open relays. The

normally closed relays can be used by changing the outputs that are wired.

Machine Stop #2

MC2

K16

J15-4

J15-5

J15-6

MC2

NC

MC2

NO

Machine Stop #1

MC1

K15

J15-1

J15-2

J15-3

Master Relay

Main Line Contactor

INPUT

Master Relay

Main Line Contactor

OUTPUT

Figure 3. Example Machine Stop Wiring

1

J27

G N L

Pre-Engineered inteleSmart2 Instruction Manual

April 2019

Page 18 of 102

4.6 WIRING DIAGRAMS

The CPU board of the inteleSmart2 contains sixteen relays. Two of these relays (K15 and K16) are used

for machine stop (MC) as described in Section 4.5, and two other relays (K13 and K14) are Form C “flip-

flop” relays. All of the other relays (K1-K12) are normally open relays where K1-K11 are single output

relays and K12 is a dual output relay. Figure 4 shows the relay wiring for all of the relays on the CPU

board.

The system comes pre-programmed; Sections 8 and 9 have individual wiring diagrams for different crane

configurations. Find the appropriate wiring diagram and, if necessary, program the receiver and

transmitter switch settings shown for the appropriate diagram. Terminal designators are marked on the

wiring diagram corresponding to designators found on the receiver board. For terminal locations refer to

Figure 2 and Figure 7. After selecting the appropriate motors for each function remember to place the

appropriate label on your transmitter for describing the appropriate command.

Typically in the following wiring diagrams, the Hoist is shown as Motor 1, Trolley as Motor 2, and Bridge is

shown as Motor 3. Make sure the transmitter is labeled with the correct functions. Stick-on or movable

button labels are provided with the transmitter for proper labeling.

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Page 19 of 102

K1

J11-6

J11-5

K2

J11-4

J11-3

K3

J11-2

J11-1

K4

J12-8

J12-7

K5

J12-6

J12-5

K6

J12-4

J12-3

K7

J12-2

J12-1

K8

J13-1

J13-2

K9

J13-3

J13-4

K10

J13-5

J13-6

K11

J13-7

J13-8

J14-6

J14-7

J14-5

K13

J14-9

J14-10

J14-8

K14

K16

J15-4

J15-5

J15-6

Machine Stop #2

MC2

K15

J15-1

J15-2

J15-3

Machine Stop #1

MC1

K12A

J14-2

J14-1

K12B

J14-4

J14-3

Figure 4: CPU Board Relay Wiring Diagram

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April 2019

Page 20 of 102

4.6.1 Wiring Isolation Options

The inteleSmart2 can be wired to provide different levels of isolation. When the unit is ordered with no

pigtail or connector option, the user can wire the relays to the level of isolation required. This can be

accomplished by referring to the wiring diagrams in Figure 4 for the main board and Figure 6for the

expansion modules.

When ordering with the pigtail connection (Magnetek P/N: IS2-PT), there is no isolation provided in the

wiring. It is possible to achieve different levels of isolation as required by the application. This can be

accomplished by utilizing any unused wire connections on the board to provide additional control voltage

feeds for the relays. There may be unused wires, depending on the pigtail configuration. The unused

wires should always be used first to achieve added isolation. After utilizing unused wire connections,

Magnetek then recommends utilizing the input power connections that are unused. If powering the unit

via AC power, then the DC input lines can be used and vice versa. If additional isolation is still required,

then the connections for the digital inputs (J16), analog input (J25), and CAN (J1) are able to be used as

required.

Magnetek does provide a fully isolated option. Full isolation is only available from Magnetek when

ordering a system with the HAN style connector (Magnetek P/N: IS2-CON).

4.7 CONNECTING OUTPUTS TO DRIVES

MOVs (transient protectors) are on all of the output relays to protect the relays from power surges. MOVs

allow a small leakage current that can affect some high impedance circuits. When connecting output

relays to drives, it may be required to remove the MOV to prevent its leakage current from holding in the

drive. The MOVs are next to the relays they protect (see Figure 2 for the location of the MOVs). The

MOVs can be cut out of the circuit with a wire cutter if required; ensure that ALL power is OFF to the

crane and all associated controls before removing the MOVs.

4.8 ANALOG INPUT

The inteleSmart2 contains one analog input that can be used to interface with an analog device such as a

load cell. Figure 5 shows the terminals that the analog input needs to be wired to. The analog input can

support a variety of different types of analog input, including 0-5VDC, 0-10VDC, 4-20mA, and 0-20mA.

In addition, there is a reference input for the analog signal. Typically this is the ground reference from the

device that the analog signal is coming from.

J

25-1

J25-2

Analog Input

Analog

Reference

Figure 5: Analog Input Wiring

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Magnetek inteleSmart2 Receiver Pre-Engineered Owner's manual

Magnetek inteleSmart2 Receiver Pre-Engineered Owner's manual

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