Magnetek Intelli-Protect NFZ-CONFIG-5050 User manual

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

Intelli-Protect User Manual
April 2023
Page 2 of 65
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: [phone]
E-mail: [e-mail]
Fax Numbers:
Main: 800.298.3503
Sales: 262.783.3510
Service: 262.783.3508
Canada
161 Orenda Road
Unit 1
Brampton, Ontario
L6W 1W3 Canada
Telephone: [phone]
Fax: [phone]
416.424.7617 (24/7 Service pager)
Europe
STAHL CraneSystems GmbH
Telephone: [phone]
E-mail: [email protected]m
Website
https://www.columbusmckinnon.com/magnetek
© 2023 Columbus McKinnon Corporation
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 the Columbus McKinnon Corporation.

Intelli-Protect User Manual
April 2023
Page 3 of 58
PREFACE AND SAFETY
Product Safety Information
Magnetek offers a broad range of radio remote control products, control products and adjustable frequency
drives, industrial braking systems, and power delivery products for 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 the 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, lifting devices or other equipment which uses or includes Magnetek products:
• Instructions, manuals, and safety warnings of the manufacturers of the equipment where the
Magnetek Products 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 Administration (OSHA),
• Applicable local, state, provincial, or federal codes, ordinances, standards and requirements, or
• Safety standards and practices for the industries in which Magnetek Products are used.
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 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. No one should use Magnetek Products prior to
becoming familiar with and being trained in these requirements and the instructions and safety
recommendations for this manual.
Product Warranty Information
For information on Magnetek’s product warranties by product type, please visit the Material Handling site
at www.columbusmckinnon.com/magnetek.

Intelli-Protect User Manual
April 2023
Page 4 of 65
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.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in 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
serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or
moderate injury. It may also be used to alert against unsafe practices.
WARNING
• Read this user manual in its entirety before installing Intelli-Protect™ software.
• DO NOT connect or disconnect wiring or perform signal checks while the electrical power is ON.
• Improper programming with this software can lead to unexpected, undesirable, or unsafe
operation.
Failure to observe these and other precautions indicated in this manual will expose the user to high
voltages, resulting in serious injury or death. Damage to equipment may also occur.

Intelli-Protect User Manual
April 2023
Page 5 of 65
NOTE: ANOTE statement is used to notify people of installation, operation, programming or maintenance
information that is important, but not hazard-related.
CAUTION
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. Nevertheless, Magnetek assumes no responsibility for errors or omissions. Neither is any
liability assumed for damages resulting from the use of the information contained in this publication.

Intelli-Protect User Manual
April 2023
Page 6 of 65
Table of Contents
1 Introduction...........................................................................................................................................8
1.1 Intelli-Protect® Products...............................................................................................................8
1.1.1 Intelli-Protect® Configurable No-Fly Zones.............................................................................9
1.1.2 Intelli-Protect® Fixed Location No-Fly Zones ........................................................................10
1.2 Intelli-Protect® Parts ..................................................................................................................11
1.3 Flexible Configurations with User Interface (UI).........................................................................11
1.4 Light Stack..................................................................................................................................12
2 Mechanical Installation .......................................................................................................................13
2.1 Environmental Ratings and Certifications ..................................................................................13
2.2 Laser Specification.....................................................................................................................14
2.3 Reflector Installation...................................................................................................................15
2.4 50 m Laser Installation and Wiring.............................................................................................16
2.4.1 50 m Laser Wiring..................................................................................................................17
2.5 150 m and 300 m Laser Installation and Wiring.........................................................................18
2.5.1 150 m and 300 m Laser Wiring..............................................................................................20
2.6 Laser Alignment Instructions......................................................................................................21
2.7 Fixed Location Installation: Windmill Switches...........................................................................21
2.7.1 Slowdown and Stop Configuration.........................................................................................22
2.7.2 Protected Zone Configuration................................................................................................23
2.8 Light Stack Installation ...............................................................................................................24
3 Power and Control Wiring...................................................................................................................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 to Configure Travel Limits ..................................................................................................33
4.3.1 Trolley Configuration Steps ...................................................................................................34
4.3.2 Bridge Configuration Steps....................................................................................................37
4.4 Zone Setup.................................................................................................................................40
4.4.1 Load Size Consideration........................................................................................................41
4.5 Enabling Zones ..........................................................................................................................42
4.6 Hoist Upper Limit and Machine Down Configuration..................................................................43
4.7 Slowdown Only Configuration ....................................................................................................44
4.8 Zone Overview...........................................................................................................................45
5 Fixed Location Setup..........................................................................................................................47
5.1 Connecting to Web Server.........................................................................................................47
5.2 Main Menu..................................................................................................................................48
5.3 Fixed Location Initial Setup........................................................................................................49
5.4 Fixed Location Test Procedure ..................................................................................................50
6 Intelli-Protect® Inputs and Outputs.....................................................................................................52
7 Troubleshooting..................................................................................................................................54
7.1 Light Stack Indicators and Corrective Actions............................................................................54
7.2 Alarms and Corrective Actions During Operation.......................................................................55
8 Magnetek Application Examples.........................................................................................................56
8.1 Connection Diagram with Magnetek Series 4 Drive...................................................................56
8.1.1 IMPULSE®·G+/VG+ Series 4 Drive Programming................................................................57
8.2 Hoist Upper Limit Switch............................................................................................................57
8.3 Machine Lowered Example........................................................................................................58
8.4 Slowdown Only Configuration ....................................................................................................59

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

Intelli-Protect User Manual
April 2023
Page 8 of 58
1 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.
These versatile systems – ranging from simple to complex configurations – can be added to existing crane
controls or introduced as new installations for a variety of industries, including automotive, steel,
manufacturing, and pulp and paper.
1.1 Intelli-Protect®Products
Intelli-Protect®Configurable and Fixed Location Description Catalog Part Number
Configurable Intelli-Protect (50 x 50 meter) NFZ-CONFIG-5050
Configurable Intelli-Protect (50 x 300 meter) NFZ-CONFIG-50300
Configurable Intelli-Protect (150 x 300 meter) NFZ-CONFIG-150300
Fixed Location Intelli-Protect NFZ-FIXED
Reflector 610 x 610 mm (24 x 24 in.) REFLX-REFLECTOR-DIN
Tablet (Optional) Contact Factory

Intelli-Protect User Manual
April 2023
Page 9 of 65
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.
Figure 1-1: Configurable NFZ Example Configurations (Overhead Traveling Bridge Crane)
• Enable and configure up to 31 No-Fly Zones
• Quickly define NFZ boundaries using two diagonal corner positions 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
• Using a PED (smartphone, tablet), open a Zone Overview screen:
– See NFZ boundaries on runway floor plan
– See updated position of the crane as it moves
– See active zone states (red - within restricted zone, yellow - within stop zone, blinking yellow -
within slowdown zone, green - outside of zone)
• Light stack with horn for visual and audible notifications
• Hoist upper travel limit switch provides the option to fly over selected zones when enabled
• Machine lowered signal provides the option to disable movement when a machine is blocking a path
(Zone 1 only)
• One external key switch to disable protection zones
• One external key switch to disable Wi-Fi

Intelli-Protect User Manual
April 2023
Page 10 of 58
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.
• Using a Personal Electronic Device (PED) (smartphone, 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 selected zones when enabled
• Machine lowered signal provides the option to disable movement when a machine is blocking a path
• One external key switch to disable protection zones
• One external key switch to disable Wi-Fi
• 4-pole normally closed limit switches are used to detect the slowdown (warning) boundary, stop
boundary crossing, and breach of a protected zone boundary
• Fixed location No-Fly Zones require trip arms to trigger the limit switches (Not provided with
Intelli-Protect)

Intelli-Protect User Manual
April 2023
Page 11 of 65
1.2 Intelli-Protect®Parts
1.3 Flexible Configurations with User Interface (UI)
Through our web-based UI, a user can perform the following standard operations using an iPhone, iPad,
Android mobile or host computer over Wi-Fi:
• Configure your factory’s Bridge and Trolley span limits
• Configure End-of-Travel Zones
• View Alarm List showing active encroachments of user-defined slowdown and stop boundaries
• Configure hoist upper travel limit or machine lowered signal to provide the option to fly over selected
zones
• Configure a zone to be slowdown only
Common Components Spec Qty
Intelli-Protect®Control Panel Includes PLC and Wi-Fi 1
Light Stack with Horn 3-segment 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
Laser 50 m 1-inch accuracy 2
Trolley Reflector T: 24 in x 24 in (61 x 61 cm) 1
Bridge Reflector B: 24 in x 24 in (61 x 61 cm) 1
Laser Mounting Bracket 50 m 2
Catalog Number NFZ-CONFIG-50300
Laser 50 m 1-inch accuracy 1
Laser 300 m 0.1 mm resolution 1
Reflectors T: 24 in x 24 in (61 x 61 cm) 1
B: 24 in x 24 in (61 x 61 cm) 6
Laser Mounting bracket 50 m 1
Laser Mounting bracket 300 m 1
Catalog Number NFZ-CONFIG-150300
Laser 150 m 0.1 mm resolution 1
Laser 300 m 0.1 mm resolution 1
Reflectors T: 24 in x 24 in (61 x 61 cm) 2
B: 24 in x 24 in (61 x 61 cm) 6
Laser Mounting bracket 300 m 2
Fixed Location Components Spec Qty
XCKMR54D1 Four Pole Limit Switch 4 x (2 NC) 4
NOTE: Trip arms for fixed location systems are not provided.

Intelli-Protect User Manual
April 2023
Page 12 of 65
1.4 Light Stack
Three-Segment light stack with horn
NOTE: If the panel bypass key switch is switched to disable the No-Fly Zone protection, the red
light will flash continuously until protection has been re-enabled by the bypass key switch. When
Bypass 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 Indicators Intelli-Protect®
Color Industry Standard No-Fly Zone
Green Safe/Normal Power on, PLC running - Solid
Amber Warning/Abnormal Within Stop Zone - Solid
Within Slowdown Zone - Flashing
Red Danger/Fault
Within Restricted Zone - Solid
Bypass - Flashing with horn sound
No Zones Configured – Flashing
with no horn

Intelli-Protect User Manual
April 2023
Page 13 of 58
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
Suitable for outdoor use. For direct sunlight or extreme temperatures, contact Columbus McKinnon.
Specification Panel
Operating Temperature 14°F to 122°F (-10°C to 50°C) max.
Vibration 3.5 mm / 3 gn at 8.4 to 150 Hz
Humidity 95% without condensation
Environmental Classification NEMA 4X / IP 56
Certification UL508A Industrial Control Panel

Intelli-Protect User Manual
April 2023
Page 14 of 65
2.2 Laser Specification
Intelli-Protect®50 x 50 m Laser Specifications
Intelli-Protect®150 and 300 m Laser Specifications
Beam Diameter at Each Distance
Figure 2-1: Beam Diameter at Each Distance (Side View of Laser)
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 1
Wavelength 660 Nm
Ambient Light Limit 50000 Lux
Weight 0.2 lb
Specification Laser
Ambient Temperature 14°F to 122°F (-10°C to 50°C)
Operating Range 0.3 to 150 m
Resolution 0.1 mm, adjustable
Laser Class Measurement laser: 1
Alignment laser: 2
Wavelength Measurement laser: 905 Nm
Alignment laser: 660 Nm
Ambient Light Limit >100000 Lux
Weight 1.5 lb
Beam Diameter:
50 m 100 m 150 m 300 m
0 m
0 m .15 m .25 m .35 m .65 m

Intelli-Protect User Manual
April 2023
Page 15 of 65
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. See Figure 2-2 below.
Figure 2-2: Mounting the Laser
Reflector Mounting Guide Reflector Layout Qty
NFZ-CONFIG-5050
Trolley Reflector 1 wide x 1 high 1
Bridge Reflector 1 wide x 1 high 1
NFZ-CONFIG-50300
Trolley Reflector 1 wide x 1 high 1
Bridge Reflector 3 wide x 2 high 6
NFZ-CONFIG-150300
Trolley Reflector 2 wide x 1 high 2
Bridge Reflector 3 wide x 2 high 6

Intelli-Protect User Manual
April 2023
Page 16 of 65
2.4 50 m Laser Installation and Wiring
The Intelli-Protect
®
50 m System measures the distance between the trolley or bridge mounted laser lens
and the target reflector. There must be no projections on the crane that may extend in front of either (or
both) the laser unit or the reflector.
Make sure the laser is mounted such that nothing can come between the laser's view of the reflector.
Determine the mounting position for the laser and the target such that the center 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 the rails. This is the most important part of a
successful installation since the laser beam must stay on the reflector at all range points anywhere in the bay.
Figure 2-3: Installing the Laser
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. Do not open the laser unit to service it since there are no serviceable parts inside.

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

Intelli-Protect User Manual
April 2023
Page 18 of 65
2.5 150 m and 300 m Laser Installation and Wiring
The Intelli-Protect
®
150 m and 300 m Systems measure the distance between the trolley or bridge
mounted laser lens and the target reflector. There must be no projections on the crane that may extend in
front of either (or both) the laser unit or the reflector.
Make sure the laser is mounted such that nothing can come between the laser's view of the reflector.
Determine the mounting position for the laser and the target such that the center 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 the rails. This is the most important part of a
successful installation since the laser beam must stay on the reflector at all range points anywhere in the
bay.
NOTE: Alignment (pointer) laser will blink at approximately 1 hz when target signal is lost, and
will flash for an additional 2 minutes before deactivating 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 enabled during setup.
The table below may be used to identify how far off center a beam may stray before a partial loss of signal
will occur.
Example: At 150 m, the infrared measurement beam diameter is 35 cm. The total reflector width of the
recommended 2-wide setup is 122 cm (61 cm reflector). There will be 43.5 cm on each side of the
measurement beam on a perfectly centered system. This is the off-center horizontal tolerance value.
Example Horizontal off-center tolerance: (122 cm - 35 cm) / 2 = 43.5 cm
Laser Beam
Diameter
Beam Tolerances Off Center Reflector Width Reflector Height
Horizontal Vertical
@ 150 m 35 cm +/- 43.5 cm +/- 13 cm 122 cm (2 wide) 61 cm (1 high)
@ 300 m 65 cm +/- 59 cm +/- 28.5 cm 183 cm (3 wide) 122 cm (2 high)
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. Do not open the laser unit to service it since there are
no serviceable parts inside.

Intelli-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 900 g

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