Magnetek Intelli-Protect NFZ-CONFIG-5050, User Manual

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Intelli-Protect User Manual

April 2023

Figure 5-1: Main Menu

5.3 Fixed Location Initial Setup

1.

Power up the system

2.

Status light Green for Power on (NO FAULT) (No Horn)

3.

Enable Hoist Upper Limit if needed

4.

Enable Machine Down if needed

5.

Status light Green (Amber if crane is still in the stop or slowdown zone)

6.

Test Zone

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Summary of Contents for Intelli-Protect NFZ-CONFIG-5050

Page 1: ...Intelli Protect User Manual Part Number 113 11850 Rev 02 April 2023 Copyright 2023 Magnetek...

Page 2: ...0 792 7253 Fax 905 828 5707 416 424 7617 24 7 Service pager Europe STAHL CraneSystems GmbH Telephone 49 7940 128 0 E mail mh eurosales magnetek com Website https www columbusmckinnon com magnetek 2023...

Page 3: ...ducts are used Plant safety rules and procedures of the employers and the owners of the facilities where the Magnetek Products are being used Regulations issued by the Occupational Health and Safety A...

Page 4: ...death or serious injury This signal word is to be limited to the most extreme situations WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serio...

Page 5: ...to the use of the information contained herein Moreover Magnetek is constantly improving its high quality product therefore the information contained in this manual is subject to change without notice...

Page 6: ...g 26 3 1 Control Inputs 26 3 2 Intelli Protect Control Outputs 29 3 2 1 Control Outputs 30 4 Configurable No Fly Zone Setup 31 4 1 Connecting to Web Server 31 4 2 Configurable Initial Setup 32 4 3 How...

Page 7: ...Intelli Protect User Manual April 2023 Page 7 of 65 8 5 Additional Slowdown and Stop Distances 60 8 6 End of Travel Zones 60 9 Appendix 62 9 1 Wireless SSID Setup and Password 62...

Page 8: ...mote controls limit switches and sensors These versatile systems ranging from simple to complex configurations can be added to existing crane controls or introduced as new installations for a variety...

Page 9: ...while positioning hoist or enter location manually Determine position using lasers for 50 150 and 300 meter spans Define bridge and trolley slow stop and protected boundaries using laser positioning...

Page 10: ...e tablet connect to controller and view inputs outputs and status information Light stack with horn for visual and audible notifications Hoist upper travel limit switch provides the option to fly over...

Page 11: ...1 Cord Grips Nylon 1 5 Cord grip grommet for installation with RJ45 connectors without removing connector Nylon with slit in grommet 1 Configurable Components Spec Qty Catalog Number NFZ CONFIG 5050 L...

Page 12: ...pass is initiated the Horn will turn on for 10 seconds and off for 10 seconds this will happen twice When the Normal Operation is initiated the Horn will sound for 2 seconds then shut off Light Indica...

Page 13: ...witch to disable Wi Fi connection after configuration 2 1 Environmental Ratings and Certifications Suitable for outdoor use For direct sunlight or extreme temperatures contact Columbus McKinnon Specif...

Page 14: ...perature 22 F to 131 F 30 C to 55 C Operating Range 8 in to 150 ft Accuracy 1 in Laser Class 1 Wavelength 660 Nm Ambient Light Limit 50000 Lux Weight 0 2 lb Specification Laser Ambient Temperature 14...

Page 15: ...on the back of the reflector should be the same direction as the laser See Figure 2 2 below Figure 2 2 Mounting the Laser Reflector Mounting Guide Reflector Layout Qty NFZ CONFIG 5050 Trolley Reflect...

Page 16: ...enter of the laser s faceplate and the center of the reflector are the same distance above the plane the crane rails are in The laser and reflector center point should also be the same distance from t...

Page 17: ...Intelli Protect User Manual April 2023 Page 17 of 65 2 4 1 50 m Laser Wiring Figure 2 4 50 m Laser Options...

Page 18: ...vating automatically When mounting reflectors keep the alignment beam laser pointer completely on target and do not allow a beam to partially fall off a reflector s edge The alignment laser should be...

Page 19: ...lli Protect User Manual April 2023 Page 19 of 65 Dimensions Figure 2 5 Laser Mounting Bracket Dimensions Technical Data Mechanical Specifications Material Zinc plated steel black Mass Approximately 90...

Page 20: ...Intelli Protect User Manual April 2023 Page 20 of 65 2 5 1 150 m and 300 m Laser Wiring Figure 2 6 150m and 300 m Laser Options...

Page 21: ...sible As soon as the distance measurement device has detected a target the laser pointer flashes for an additional two minutes before deactivating automatically Run the crane to test and verify the la...

Page 22: ...tion that will be called Forward Likewise for bridge motions along a runway choose a direction that will be called Forward Then follow the windmill diagrams below to mount the switches NOTE Trip arms...

Page 23: ...ct User Manual April 2023 Page 23 of 65 2 7 2 Protected Zone Configuration The following diagrams show how to correctly wire the protected zone four pole switches according to the user selected direct...

Page 24: ...3 Page 24 of 65 2 8 Light Stack Installation The light stack that is provided with the Intelli Protect No Fly Zone includes a horn to provide visual and audible notifications Install the light stack i...

Page 25: ...Intelli Protect User Manual April 2023 Page 25 of 65 Horn Green Yellow Red IOLink Connection Point Extension Base Wiring...

Page 26: ...cation No Fly Zones to permit the crane to go over the top of a No Fly Zone Field wiring and circuit design is done on site by the customer and needs to take into account all hoists and zones Machine...

Page 27: ...Figure 3 2 Enclosure Overlay Drawing Circuit Breakers Main Power INT Internal components EXT External components Power Supply Wi Fi Access Point Intelli Protect Controller Ethernet Switch Control Out...

Page 28: ...Intelli Protect User Manual April 2023 Page 28 of 65 Figure 3 3 Internal Power Diagram for reference only...

Page 29: ...system panel locate the terminal block corresponding to the indicated relay labels Factory installed jumpers are included to provide discrete outputs for motor control side dry contact inputs which ca...

Page 30: ...tside of the No Fly Zone Stop Boundary If the crane enters the Stop Zone these relays would change state Forward Reverse Fast Permissive used to allow the bridge or trolley to run at full speed Forwar...

Page 31: ...and locate the MagnetekNFZ network b Enter the default password MagnetekNFZ Step 3 Open the NFZ Configuration page through the browser Open a browser such as Chrome Safari or Edge and enter the follow...

Page 32: ...bridge and trolley distances 4 Configure Zone 1 a Teach corner 1 by moving the crane or entering the data manually b Teach corner 2 by moving the crane or entering the data manually c Enable Hoist Up...

Page 33: ...t appears separately and includes specific programming steps Begin with establishing the length of the Trolley and Bridge limit After setting the Bridge and Trolley limits you may continue ahead to co...

Page 34: ...ice to set up a temporary test zone in an open area After setting up this test zone set the expected distances required to slow down and stop the crane Once these values are entered move the crane at...

Page 35: ...Intelli Protect User Manual April 2023 Page 35 of 65 Figure 4 2 Zone Configuration...

Page 36: ...ove Trolley to the End of Travel position where the laser value is the maximum f Press the Teach Max button g Move Trolley to the End of Travel position where the laser value is minimum h Press the Te...

Page 37: ...distances required to slow down and stop the crane Once these values are entered move the crane at maximum speed toward the test zone in order to determine if the slowdown distance value entered is l...

Page 38: ...Intelli Protect User Manual April 2023 Page 38 of 65 Figure 4 4 Zone Configuration...

Page 39: ...ove Bridge to the End of Travel position where the laser value is the maximum f Press the Teach Max button g Move Bridge to the End of Travel position where the laser value is minimum h Press the Teac...

Page 40: ...tion of the zone Position the hoist at the diagonal corner of the desired zone and press the Teach Diagonal Corner button to store the corner position and finalize the zone If needed the data can be e...

Page 41: ...width of the largest materials being moved should guide the design of the zone to allow enough distance for slow down zone stop zone and protected zone In addition to the length and width the height o...

Page 42: ...press the enable button on the configuration screen The enabled zone will now appear on the Overview screen Use the enable disable check box for maintenance in a zone changing the dimensions or movin...

Page 43: ...uring the No Fly Zone the dimensions of the material being moved by the overhead crane and hoist needs to be considered The length and width of the largest materials being moved should guide the desig...

Page 44: ...slowdown only zones can be configured to allow fast motion in either the bridge or trolley direction This is useful in cases where you want to enter a slowdown zone quickly and then limit the speed o...

Page 45: ...hoist crosses into the stop region the icon will display a solid AMBER Zone A fault will occur if the NFZ protected boundary is penetrated The icon background will change to RED 1 Zone Overview a All...

Page 46: ...Intelli Protect User Manual April 2023 Page 46 of 65 Figure 4 12 Zone Overview Setup...

Page 47: ...NFZ Configuration page through the browser Open a browser such as Chrome Safari or Edge and enter the following IP address in the search bar or scan QR code to access the configuration page IP Addres...

Page 48: ...al block for a fly over No Fly Zone An optional Machine Down input is available on the Power and Control Wiring terminal block for a fly over No Fly Zone CAUTION When configuring the No Fly Zone the d...

Page 49: ...n Menu 5 3 Fixed Location Initial Setup 1 Power up the system 2 Status light Green for Power on NO FAULT No Horn 3 Enable Hoist Upper Limit if needed 4 Enable Machine Down if needed 5 Status light Gre...

Page 50: ...uts screen displays a WHITE Trolley Fast Permissive output c Verify the Outputs screen displays a WHITE Bridge Fast Permissive output d Verify the direction of the Trolley slowdown output agrees with...

Page 51: ...r example A single Trolley slowdown and stop output pair should be active The direction of travel should match A single Bridge slowdown and stop output pair should be active The direction of travel sh...

Page 52: ...Zone Bypass Indicator BLUE NFZ is Disabled Bypass Key is Enabled WHITE NFZ is Enabled Bypass Key is Disabled b Hoist Upper Limit Indicator WHITE Hoist Lowered BLUE Hoist at upper limit c Machine Down...

Page 53: ...lley Motion GREEN Fast Permissive active GREEN Permissive active WHITE Inactive b Hoist Lower Permissive GREEN Allowed WHITE Not Allowed c Clear of Machine GREEN Clear WHITE Not Clear d Control Fault...

Page 54: ...flashes if no zones are configured such as on initial startup In this state the red light will flash until at least one zone is enabled The red light is turned off when in normal operation outside a N...

Page 55: ...Trolley laser lens with a lens tissue or cleaning cloth Using a circular motion gently remove oil fingerprints and grime from the lens surface 2 Clean the reflector surface to remove oil fingerprints...

Page 56: ...4 Drives TFP TRFP TRP BFFP BFP BRFP BRP TFFP 11 11 11 11 11 11 11 11 14 14 14 14 14 14 14 14 Parameters H01 05 0A Upper Lmt 1 N C H01 06 0B Upper Lmt 2 N C H01 07 0C Lower Lmt 1 N C H01 08 0D Lower Lm...

Page 57: ...mit Switch An optional Hoist Upper Limit input is available on the Power and Control Wiring terminal block for all zones Select the UI Zone Configuration checkbox Hoist Upper Limit to flyover the sele...

Page 58: ...The Machine Lowered input will allow the crane operator to fly over the top of a No Fly Zone This is available on the single fixed location No Fly Zone or on Zone 1 only of the configurable No Fly Zon...

Page 59: ...very zone This zone type does not cause the crane to come to a complete stop It can be enabled to trigger slowdown in the trolley direction or the bridge direction or both trolley and bridge direction...

Page 60: ...system allows you to include additional slowdown and or stop distances for each individual zone 8 6 End of Travel Zones Zones 28 through 31 will be dedicated for End of Travel Zones which will prevent...

Page 61: ...Intelli Protect User Manual April 2023 Page 61 of 65 Figure 8 6 EOT Zone 1 and EOT Zone 1 Advanced...

Page 62: ...1 Using a web browser such as Internet Explorer Chrome or Edge type 192 168 1 4 default web server IP address 2 Enter login id magnetek password magnetek 3 Select Wireless tab Basic Settings to change...

Page 63: ...Intelli Protect User Manual April 2023 Page 63 of 65 4 Select Wireless tab Wireless Security to change password...

Page 64: ......

Page 65: ...Intelli Protect User Manual Part Number 113 11850 Rev 02 April 2023...

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