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

Magnetek Intelli-Protect NFZ-CONFIG-5050 User Manual

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Intelli-Protect
®
User Manual
Part Number: 113-11850 Rev 02
April 2023
© Copyright 2023 Magnetek

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

  • Page 1 Intelli-Protect ® User Manual Part Number: 113-11850 Rev 02 April 2023 © Copyright 2023 Magnetek...
  • Page 2 SERVICE INFORMATION For questions regarding service or technical information contact: 1.866.MAG.SERV (1.866.624.7378) International Service Outside the U.S. and Canada call +1.262.783.3500, press 3. Columbus McKinnon Corporation Locations Magnetek N49 W13650 Campbell Drive Menomonee Falls, WI 53051 Telephone: 800.288.8178 E-mail: field.service@magnetek.com...
  • Page 3 It is the responsibility of the owners, users and operators of the Magnetek Products to know, understand and follow all these requirements. It is the responsibility of the employer to make its employees aware of all the above listed requirements and to make certain that all operators are properly trained.
  • Page 4 DANGER, WARNING, CAUTION and NOTE Statements Read and understand this manual before installing, operating, or servicing this product. The following conventions indicate safety messages in this manual. Failure to heed these messages could cause fatal injury or damage products and related equipment and systems. DANGERS, WARNINGS and CAUTIONS Throughout this document DANGER, WARNING and CAUTION statements have been deliberately placed to highlight items critical to the protection of personnel and equipment.
  • Page 5 No patent liability is assumed with respect 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. Every precaution has been taken in the preparation of this document.

  • Page 6: Table Of Contents

    Light Stack Indicators and Corrective Actions................54 Alarms and Corrective Actions During Operation............... 55 Magnetek Application Examples......................56 Connection Diagram with Magnetek Series 4 Drive..............56 8.1.1 IMPULSE®·G+/VG+ Series 4 Drive Programming ..............57 Hoist Upper Limit Switch ......................57 Machine Lowered Example ......................
  • Page 7 Additional Slowdown and Stop Distances .................. 60 End of Travel Zones ........................60 Appendix............................. 62 Wireless SSID Setup and Password ..................62 Intelli-Protect User Manual April 2023 Page 7 of 65...

  • Page 8: Introduction

    Protect personnel and valuable assets with Intelli-Protect No-Fly Zone systems. No-Fly zones (NFZs) ® refer to protected areas where normal crane operation is limited or entirely restricted. Magnetek-brand ® Intelli-Protect Systems, part of the Intelli-Crane™ portfolio of products, allow you to designate locations where a crane is programmed to slow down or stop, using motion control products such as variable- frequency drives, radio remote controls, limit switches, and sensors.

  • Page 9: Intelli-Protect Configurable No-Fly Zones

    1.1.1 Intelli-Protect Configurable No-Fly Zones ® Configurable No-Fly Zone systems utilize laser positioning sensors installed on bridge/trolley motions that interface with a No-Fly Zone controller. This system incorporates a simplified menu-driven operator interface accessed over a wireless connection via the use of a Personal Electronic Device (PED) such as a laptop, smartphone, or tablet.

  • Page 10: Intelli-Protect Fixed Location No-Fly Zones

    1.1.2 Intelli-Protect Fixed Location No-Fly Zones ® Fixed location No-Fly Zones systems utilize limit switches installed on bridge/trolley motions that interface with a No-Fly Zone controller. Figure 1-2: Four-Sided Fixed Location NFZ Example (Overhead Traveling Bridge Crane) • Detect slowdown, stop, and protected boundaries using windmill limit switches for bridge and trolley motions.

  • Page 11: Intelli-Protect Parts

    1.2 Intelli-Protect ® Parts Common Components Spec Intelli-Protect Control Panel Includes PLC and Wi-Fi ® Light Stack with Horn 3-segment Cord Grips Nylon Cord grip grommet for installation with RJ45 Nylon with slit in grommet connectors without removing connector Configurable Components Spec Catalog Number NFZ-CONFIG-5050 Laser 50 m...

  • Page 12: Light Stack

    1.4 Light Stack Three-Segment light stack with horn Light Indicators Intelli-Protect ® Color Industry Standard No-Fly Zone Green Safe/Normal Power on, PLC running - Solid Within Stop Zone - Solid Amber Warning/Abnormal Within Slowdown Zone - Flashing Within Restricted Zone - Solid Bypass - Flashing with horn sound Danger/Fault No Zones Configured –...

  • Page 13: Mechanical Installation

    2 Mechanical Installation • External panel-mounted key switch to disable protection zones and allow movement into all zones • Padlock provision is included • External mounted key switch to disable Wi-Fi connection after configuration 2.1 Environmental Ratings and Certifications Specification Panel Operating Temperature 14°F to 122°F (-10°C to 50°C) max.

  • Page 14: Laser Specification

    2.2 Laser Specification Intelli-Protect 50 x 50 m Laser Specifications ® Specification Laser Operating Temperature -22°F to 131°F (-30°C to 55°C) Operating Range 8 in. to 150 ft Accuracy 1 in. Laser Class Wavelength 660 Nm Ambient Light Limit 50000 Lux Weight 0.2 lb Intelli-Protect...

  • Page 15: Reflector Installation

    2.3 Reflector Installation For best reflectivity/laser signal, mount the reflector in the same orientation as the laser so the laser beam is perpendicular to the reflector. The arrow on the back of the reflector should be the same direction as the laser.

  • Page 16: 50 M Laser Installation And Wiring

    2.4 50 m Laser Installation and Wiring CAUTION Intelli-Protect 50 m Configurable systems contain Class 1 lasers with a 660 Nm wavelength. Although ® the laser is eye-safe, it is recommended that no one look directly into the laser with their eye close to the lens of the laser unit.

  • Page 17: 50 M Laser Wiring

    2.4.1 50 m Laser Wiring Figure 2-4: 50 m Laser Options Intelli-Protect User Manual April 2023 Page 17 of 65...

  • Page 18: 150 M And 300 M Laser Installation And Wiring

    2.5 150 m and 300 m Laser Installation and Wiring CAUTION Intelli-Protect 150 and 300 m Configurable systems contain Class 1 measurement and Class 2 ® alignment lasers with visible and invisible laser radiation. Do not look at the beam. The irradiation can lead to irritation especially in a dark environment.
  • Page 19 Dimensions Figure 2-5: Laser Mounting Bracket Dimensions Technical Data Mechanical Specifications Material Zinc-plated steel, black Mass Approximately 900 g Intelli-Protect User Manual April 2023 Page 19 of 65...

  • Page 20: 150 M And 300 M Laser Wiring

    2.5.1 150 m and 300 m Laser Wiring Figure 2-6: 150m and 300 m Laser Options Intelli-Protect User Manual April 2023 Page 20 of 65...

  • Page 21: Laser Alignment Instructions

    2.6 Laser Alignment Instructions 1. The factory default setting for the laser pointer in the menu is “Auto.” – If the sensor does not detect a target, the laser pointer flashes at a frequency of approximately 1 Hz. – Perform the alignment at the maximum possible distance. 2.

  • Page 22: Slowdown And Stop Configuration

    All switches must be installed with the same understanding of the direction of travel to achieve successful operation. For trolley motions spanning the bridge, choose a direction 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.

  • Page 23: Protected Zone Configuration

    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 direction of travel. Intelli-Protect User Manual April 2023 Page 23 of 65...

  • Page 24: Light Stack Installation

    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 in a location visible to the operator. Intelli-Protect User Manual April 2023 Page 24 of 65...
  • Page 25 Horn Green Yellow IOLink (Connection Point) Extension Base Wiring Intelli-Protect User Manual April 2023 Page 25 of 65...

  • Page 26: Power And Control Wiring

    3 Power and Control Wiring The following diagram shows terminal block connection points for power and control wiring for both configurable and fixed No-Fly Zones. 115 VAC, 3 Amp, 60 Hz is customer supplied. Power and control wiring should follow all necessary national and local standards. Figure 3-1: Terminal Block Connection Points 3.1 Control Inputs •...
  • Page 27 Circuit Breakers Main Power INT - Internal components Wi-Fi EXT - External components Access Point Power Intelli-Protect Controller Supply Ethernet Switch Control Outputs Power and Control Wiring Inputs IO-Link Module Figure 3-2: Enclosure Overlay Drawing Intelli-Protect User Manual April 2023 Page 27 of 58...
  • Page 28 Figure 3-3: Internal Power Diagram (for reference only) Intelli-Protect User Manual April 2023 Page 28 of 65...

  • Page 29: Intelli-Protect Control Outputs

    3.2 Intelli-Protect ® Control Outputs Inside the 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 can be removed if wiring pendant or radio control signals through these relays. Figure 3-4: Relay Labels Intelli-Protect User Manual April 2023...

  • Page 30: Control Outputs

    3.2.1 Control Outputs Designed for fail-safe operation, the control outputs are wired to an external controller, drive or contact that controls the trolley, bridge and hoist motions. The Fast Permissive will allow the bridge or trolley to run at full speed when outside of the No-Fly Zone Slow Down Boundary. If the crane enters the Slow Down Zone these relays would change state.

  • Page 31: Configurable No-Fly Zone Setup

    4 Configurable No-Fly Zone Setup 4.1 Connecting to Web Server Step 1. Set up network connection to the web server. Ensure the wireless connection to your Intelli-Protect panel is turned on and the control ® panel is powered up. NOTE: You may disable the Intelli-Protect Wi-Fi system using the Wi-Fi key switch on the front panel after configuration to avoid interference with other wireless systems.

  • Page 32: Configurable Initial Setup

    Config Screens Trolley – Setup Trolley Span, and Slow and Stop Distance Bridge – Setup Bridge Span, and Slow and Stop Distance Zone – Setup and enable / disable up to 31 No-Fly zones 4.2 Configurable Initial Setup For initial setup and zone configuration the following steps should be implemented: 1.

  • Page 33: How To Configure Travel Limits

    4.3 How to Configure Travel Limits Before defining your custom NFZs, follow the steps below to set your unique trolley and bridge span for the bay the crane is operating in. Each main menu button opens a screen that appears separately and includes specific programming steps. Begin with establishing the length of the Trolley and Bridge limit.

  • Page 34: Trolley Configuration Steps

    If using Magnetek-brand Sway Control software, make sure to perform the slowdown and stop distance measurements and configuration with the Sway Control feature enabled. Using Sway Control with Intelli-Protect requires the most recent Magnetek VFD firmware release.
  • Page 35 Figure 4-2: Zone Configuration Intelli-Protect User Manual April 2023 Page 35 of 65...
  • Page 36 1. Trolley Configuration a. Press the Forward Description text box b. Enter the desired description for Forward c. Press the Reverse Description text box d. Enter the desired description for Reverse e. Move Trolley to the End of Travel position where the laser value is the maximum Press the Teach Max button g.

  • Page 37: Bridge Configuration Steps

    If using Magnetek-brand Sway Control software, make sure to perform the slowdown and stop distance measurements and configuration with the Sway Control feature enabled. Using Sway Control with Intelli-Protect requires the most recent Magnetek VFD firmware release.
  • Page 38 Figure 4-4: Zone Configuration Intelli-Protect User Manual April 2023 Page 38 of 65...
  • Page 39 1. Bridge Configuration a. Press the Forward Description text box b. Enter the desired description for Forward c. Press the Reverse Description text box d. Enter the desired description for Reverse e. Move Bridge to the End of Travel position where the laser value is the maximum Press the Teach Max button g.

  • Page 40: Zone Setup

    4.4 Zone Setup To configure the location of a No-Fly Zone, first disable the zone by clearing the ‘Enable’ checkbox. On initial setup, all zones are disabled by default. Each zone is numbered from 1 to 31. Use the Previous and Next buttons at the top of the menu to scroll between all 31 zone configurations.

  • Page 41: Load Size Consideration

    4.4.1 Load Size Consideration When configuring 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 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 of the material needs to be taken into account for fly-over No- Fly Zones when using the Hoist Upper Limit input or Machine Down input to insure proper clearance over the top of the protected zone.

  • Page 42: Enabling Zones

    4.5 Enabling Zones After completing the setup of the trolley, bridge spans, the Slow Down Zone, Stop Zone and Protected Zone, 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 moving the zone to a new location.

  • Page 43: Hoist Upper Limit And Machine Down Configuration

    4.6 Hoist Upper Limit and Machine Down Configuration A No-Fly Zone can be bypassed if all the hoists are at an upper limit or the equipment/machine is in the down position. The inputs are provided by the customer to the NFZ controller from the hoist or equipment / machine.

  • Page 44: Slowdown Only Configuration

    4.7 Slowdown Only Configuration A Slowdown Only Zone option can be configured for every zone. When the crane enters the slowdown only zone, the crane will slowdown but it will not stop. Additionally, 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 of the other direction once you are in the slowdown zone.

  • Page 45: Zone Overview

    4.8 Zone Overview The Zone Overview screen displays the position, relative size and state of all enabled NFZs. If a hoist moves into the slowdown region of a zone, the icon will display a blinking AMBER Zone. If a 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.
  • Page 46 Figure 4-12: Zone Overview Setup Intelli-Protect User Manual April 2023 Page 46 of 65...

  • Page 47: Fixed Location Setup

    5 Fixed Location Setup 5.1 Connecting to Web Server Step 1. Set up network connection to the web server. Ensure the wireless connection to your Intelli-Protect panel is turned on and the control ® panel is powered up. NOTE: You may disable the Intelli-Protect Wi-Fi system using the Wi-Fi key switch on the front panel after configuration to avoid interference with other wireless systems.

  • Page 48: Main Menu

    Config Screens Enable/Disable Hoist Upper Limit Enable/Disable Machine Down 5.2 Main Menu A fixed location system will display the following main screen. Input, output and alarm screens will display the current state of the Intelli-Protect ® system. A fly-over No-Fly zone can be configured if all the hoists are at an upper limit or the equipment or machine is in the down position.

  • Page 49: Fixed Location Initial Setup

    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.

  • Page 50: Fixed Location Test Procedure

    5.4 Fixed Location Test Procedure After mounting the first pair of corner trip arms at an outer slowdown boundary (Bridge slowdown and Trolley slowdown) and wiring the limit switches, move the crane into a position that trips both the Bridge and Trolley 4-pole limit switches.
  • Page 51 If the first limit switch test displayed a Bridge slowdown FWD, this limit switch test should display a Bridge stop FWD, for 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.

  • Page 52: Intelli-Protect Inputs And Outputs

    ® 6 Intelli-Protect Inputs and Outputs Intelli-Protect supports the following system inputs and outputs that provide status indicators to aid in ® setup and troubleshooting: 1. Inputs a. Zone Bypass Indicator BLUE = NFZ is Disabled (Bypass Key is Enabled) WHITE = NFZ is Enabled (Bypass Key is Disabled) b.
  • Page 53 The output screen provides status indication for outputs from the No-Fly Zone controller. The indicators will match the external light stack provided with the system. 1. Outputs a. Bridge and Trolley Motion GREEN = Fast Permissive active GREEN = Permissive active WHITE = Inactive b.

  • Page 54: Troubleshooting

    7 Troubleshooting 7.1 Light Stack Indicators and Corrective Actions Light Stack Fault Indicator Fault Name / Description Corrective Action Solid Red light on Light Stack Zone [number] Breached Disable the No-Fly Zone using the key appears in Alarm List. switch on the front of the enclosure DANGER Manually move the crane out of the zone...

  • Page 55: Alarms And Corrective Actions During Operation

    7.2 Alarms and Corrective Actions During Operation Example alarms on configurable systems: Figure 7-1: Alarm Examples Alarm Description Corrective Action Bridge Sensor Fault Sensor is not receiving a Clean the Bridge or Trolley laser lens strong enough signal. with a lens tissue or cleaning cloth. Trolley Sensor Fault Using a circular motion, gently remove oil, fingerprints, and grime from the lens...

  • Page 56: Magnetek Application Examples

    H01-06 = 0B (Upper Lmt 2 N.C.) H01-07 = 0C (Lower Lmt 1 N.C.) H01-08 = 0D (Lower Lmt 2 N.C.) S4IF BFFP BRFP Figure 8-1: Example Connections to Magnetek IMPULSE·G+/VG+ Series 4 Drives Intelli-Protect User Manual April 2023 Page 56 of 58...

  • Page 57: Impulse®·G+/Vg+ Series 4 Drive Programming

    8.1.1 IMPULSE ·G+/VG+ Series 4 Drive Programming ® For IMPULSE·G+/VG+ drives, use the following parameter settings. Using the control signal outputs from the Intelli-Protect controller, wire the permissive outputs to the Magnetek trolley, bridge and hoist drives. Parameter Value Display...

  • Page 58: Machine Lowered Example

    8.3 Machine Lowered Example An optional Machine Lowered input is available on the Power and Control Wiring terminal block. 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 Zones.

  • Page 59: Slowdown Only Configuration

    Figure 8-4: Advanced Setup Machine Down 8.4 Slowdown Only Configuration A Slowdown Only Zone option can be configured for every 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 directions while within the zone.
  • Page 60 Figure 8-5: Advanced Setup Slowdown Only 8.5 Additional Slowdown and Stop Distances Slowdown and Stop Distances are setup in the Trolley and Bridge configuration menus. These distances apply to all zones and need to be setup according to the speed and deceleration rates of the crane (they also need to factor in the dimensions of the load).
  • Page 61 Figure 8-6: EOT Zone 1 and EOT Zone 1 Advanced Intelli-Protect User Manual April 2023 Page 61 of 65...
  • 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 SSID. NOTE: After applying settings, press “Save” to ensure changes are saved in the event of power loss.
  • Page 63 4. Select Wireless tab ->Wireless Security to change password. Intelli-Protect User Manual April 2023 Page 63 of 65...
  • Page 65 Intelli-Protect User Manual Part Number 113-11850 Rev 02 April 2023...

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