Magnetek Flex 12EX2 Instruction Manual
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Magnetek Flex 12EX2 Instruction Manual

Flex 12ex gen2 series radio control equipment
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Flex 12EX Gen2 System
Radio Control Equipment
Instruction Manual
Part Number: 191-51200-M000F R00
November 2017
©Copyright 2017 Magnetek Material Handling

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Summary of Contents for Magnetek Flex 12EX2

  • Page 1 Flex 12EX Gen2 System Radio Control Equipment Instruction Manual Part Number: 191-51200-M000F R00 November 2017 ©Copyright 2017 Magnetek Material Handling...
  • Page 2 Page Intentionally Left Blank Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 2 of 56...

  • Page 3: Table Of Contents

    System Channels Table......................43 Receiver Installation.........................44 Output Relay Contact Diagrams....................44 5.1.1 Flex 12EX2 (dual speed model) ....................44 Pre-installation Precautions......................44 Step-by-Step Installation ......................45 Operating Procedures ........................48 General Operation........................48 Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 3 of 56...
  • Page 4 System Status Light Indications ....................54 6.9.1 Transmitter Status Indications ....................54 6.9.2 Receiver Status Indications ....................55 6.9.3 Receiver Power Indications ....................55 6.9.4 Receiver COM Indications .....................55 General Specifications ........................56 Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 4 of 56...

  • Page 5: Service Information

    SERVICE INFORMATION Your New Radio Remote Control System Thank you for your purchase of Magnetek’s Flex EX2 Radio Remote Equipment Control. Magnetek has set a whole new standard in radio remote performance, dependability, and value with this unique new line of handheld transmitters.

  • Page 6: Product Manual Safety Information

    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.

  • Page 7: Introduction

    Other Optional Accessories and Features – transmitter magnet mount, transmitter belt clip, transmitter lanyard, transmitter rubber guard, miniature indicator light and buzzer, charging station, tandem function, random access function, multiple receivers function, and many others. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 7 of 56...

  • Page 8: Radio Controlled Safety

    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. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 8 of 56...

  • Page 9: Critical Installation Considerations

    Radio controlled cranes, hoists, lifting devices and other material handling equipment should not be operated by any person who cannot read or understand signs, notices and operating instructions that pertain to the equipment. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 9 of 56...

  • Page 10: Safety Information And Recommended Training For Radio Controlled Equipment Operators

    • leave any load unattended while lifted • leave power on the radio controlled equipment when the equipment is not in operation Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 10 of 56...

  • Page 11: Transmitter Unit

    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.

  • Page 12: General System Information

    Pushbutton 6 (PB6) Lanyard and Waist Belt Attachment Slot Pushbutton 7 (PB7) NOTE: Flex 12EX2-AB and 12EX2-T models have the A/B/A+B rotary switch on PB12 slot. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 12 of 56...

  • Page 13: Internal Illustration

    I-Chip Slot Status LED Indicator Function Dipswitch A/B/C/D LED Indicators Programming Port NOTE: Flex 12EX2-AB and 12EX2-T models have the A/B/A+B rotary switch on PB12 slot. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 13 of 56...

  • Page 14: Receiver

    Remote Pairing Button COM LED Indicator System Information Status LED Indicator Cord Grip Power LED Indicator Mounting Bracket Output Relay LED Indicators Mounting Bracket Release Infrared Sensors Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 14 of 56...

  • Page 15: Internal Illustration

    Internal Illustration Decoder Board Function Jumpers RF Transceiver Board Channel Dipswitch INT/EXT Antenna Jumpers AC Line Filter/Relay Board Programming Port Power Transformer Function Dipswitches Voltage Selector Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 15 of 56...

  • Page 16: Function Settings

    “channel unassigned” the receiver must also set to “channel unassigned” in order for the entire system to work. 7. Exit Channel Setting mode by rotating the power switch key to OFF ( 0 ) position. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 16 of 56...
  • Page 17 (new vs. old). In this case you would have to redo steps 1-4 and step 6 to transfer the newly selected transmitter channel to the receiver. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 17 of 56...

  • Page 18: Remote Pairing

    (press and hold PB2) (press and hold PB1) NOTE: During remote pairing make sure the distance between the two transmitters is no more than 1 meter. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 18 of 56...

  • Page 19: I-Chip

    When an I-Chip is inserted into the Flex EX2 transmitter it becomes backwards compatible with a Flex EX (GEN 1) receiver. Refer to the appropriate Flex EX (GEN 1) manual for information on configuring the I-Chip or contact Magnetek field service.

  • Page 20: Transmitter Start Function Settings

    1 minute xxx100xxxx 10 minutes xxx001xxxx 20 seconds xxx101xxxx 30 minutes xxx010xxxx 3 minutes xxx110xxxx 60 minutes Constant On (sleep xxx011xxxx 5 minutes xxx111xxxx mode disabled) Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 20 of 56...

  • Page 21: Transmitter Output Power Settings

    146 (Status LED blinks 1 orange, 4 greens and 6 reds). 7. Exit Pushbutton Function mode by rotating the power switch key to OFF ( 0 ) position. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 21 of 56...
  • Page 22 LED 4 * PB1...PB12 → Pushbutton number. * Normal → Normal momentary contact. * LED 1 - LED 4 → Pushbutton toggled function with designated LED indication. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 22 of 56...
  • Page 23 8 Greens + 3 Reds Normal Normal A/1&2 Normal 8 Greens + 4 Reds Normal Normal B/1&2 Normal 8 Greens + 5 Reds Normal Normal C/1&2 Normal Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 23 of 56...
  • Page 24 D/1&2 D/3&4 * PB9…PB12 → Pushbutton number. * Normal → Normal momentary contact. * A/1&2 - D/3&4 → A/B pushbutton select function with designated LED indication. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 24 of 56...
  • Page 25 LED 4 * PB1…PB12 → Pushbutton number. * Normal → Normal momentary contact. * LED 1 - LED 4 → Pushbutton toggled function with designated LED indication. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 25 of 56...
  • Page 26 + 3 Reds 1 Orange + 2 Greens B/1&2 C/3&4 Normal Normal + 4 Reds 1 Orange + 2 Greens B/1&2 D/3&4 Normal Normal + 5 Reds Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 26 of 56...
  • Page 27 2 Reds 1 Orange + 5 Greens + Normal Normal B/1&2 D/3&4 3 Reds 1 Orange + 5 Greens + Normal Normal C/1&2 C/3&4 4 Reds Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 27 of 56...

  • Page 28: Display Frequency Band

    Up to 4 assignable relay outputs can be programmed into the system and feedback to the transmitter LED indicators during operation. These settings require using the infrared IR programmer unit. Please contact Magnetek field service for more details. Flex 12EX2 Standard, AB and Tandem Instruction Manual...

  • Page 29: Zero-G Sensor Settings

    MAIN relays are deactivated with the exception of the horn output that can be assigned to any of the Function output relays (K25, K26 or K30). This horn output setting requires the infrared IR programmer unit. Please contact Magnetek field service for more details.
  • Page 30 TYPE E: A, B, C, D Receiver Select with Bridge Receiver TYPE F: A, B, C, D Receiver Select with Bridge 1, 2 Select Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 30 of 56...

  • Page 31: Receiver

    Output relays with Forward 1st speed (F1), Reverse 1st speed (R1) and Forward/ Reverse 2nd speed (F/R2). Forward and Reverse 2nd speed (F/R2) share the same output relay. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 31 of 56...
  • Page 32 (F2) and Reverse 2nd speed (R2). Forward and Reverse 2nd speed are separate output relays. 4.2.2.2 Output Relay Actions at 2nd Speed (Flex 12EX2 only) 1. 3 output relays configuration with Closed/Closed contact at 2nd speed F1 (or R1) output relay closed at 1st speed and F1 + F/R2 (or R1 + F/R2) output relays closed at 2nd speed.
  • Page 33 (or Rev + Slow + Fast) output relays closed at 2nd speed. See Section 4.2.3.1 on page 36 on how to set to this function. Forward 1 speed pushbutton pressed Forward 2 speed pushbutton pressed ↓ ↓ Slow Fast Slow Fast Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 33 of 56...
  • Page 34 This type of relay action usually applies to external applications such as lights. See Section 4.2.3.2 on page 37 on how to set to this function. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 34 of 56...
  • Page 35 1 2 3 * Channel X → channel set on the Channel dipswitch. ** Contact Magnetek field service if your application requires scan- ning more than 4 channels. Example: If the first 6 dipswitch positions are set to channel 01 (000001), when set to 2-channel scanning (type 2 above) the receiver will scan only channel 01 and 02.

  • Page 36: Dipswitch Settings

    3 output relays Closed/Closed relay action + External 00100100 warning* 4 output relays Opened/Closed relay action + External 00100110 warning* 01000010 4 output relays Closed/Closed relay action + Brake Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 36 of 56...
  • Page 37 Each dipswitch on the decoder board corresponds to a pushbutton pair. Only the first 7 dipswitch positions are used (counting from left to right). The 8th dipswitch position (far right) is not used. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 37 of 56...
  • Page 38 Example #1: Left button (set to function code A) / right button (set to function code B) → 1 000 001 Example #2: Left button (set to function code C) / right button (set to function code D) → 1 011 100 Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017...

  • Page 39: Jumper Settings

    For system testing only (receiver MAIN relays disabled) (Inserted) Receiver-to-transmitter remote pairing (Opened) (pressing the Pairing button required) Receiver-to-transmitter remote pairing (Inserted) (pressing the Pairing button not required) Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 39 of 56...

  • Page 40: Voltage Settings

    CN11 port located on the AC line filter/relay board inside the receiver. Contact Magnetek field service if you would like the indicator light or the buzzer to work differently. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 40 of 56...

  • Page 41: Other Function Output Relays Settings

    TYPE E: A, B, C, D Receiver Select with Bridge Receiver -12 Button Transmitter (bottom four buttons for A, B, C, D Select) -5 Receivers (A, B, C, D and Bridge) Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 41 of 56...
  • Page 42 Receiver B setting for PB5 through PB8 (Inserted) (Opened) (receiver select configuration) Receiver C setting for PB9 through PB12 (Opened) (Inserted) (receiver select configuration) NOTE: All settings are preset at the factory. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 42 of 56...

  • Page 43: System Channels Table

    011101 111100 011110 111101 011111 111110 NOTE: Channel unassigned is represented by “000000” dipswitch setting. See Section 4.1.2 on page 16, part A unassigned channel scheme. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 43 of 56...

  • Page 44: Receiver Installation

    4. Make sure the power source to the receiver is set correctly. 5. Switch off the main power source to the crane or equipment prior to installation. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 44 of 56...

  • Page 45: Step-By-Step Installation

    5.3 Step-by-Step Installation Mounting Bracket Type 1 Mounting Bracket Type 2 Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 45 of 56...
  • Page 46 9. Slide down the receiver along the guided track to secure the receiver to the mounting bracket. 10. Remove the receiver by pressing down the bracket release and pulling the receiver upward until it clears the guided track. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 46 of 56...
  • Page 47 Install Mounting Bracket Type 1 Mounting Bracket Type 2 Remove Mounting Bracket Type 1 Mounting Bracket Type 2 Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 47 of 56...

  • Page 48: Operating Procedures

    20). The Status LED blinks 3 reds and then shuts off. Press any pushbutton or execute the START command to resume operation (see Section 4.1.5 Transmitter Start Function Settings on page 20). Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 48 of 56...

  • Page 49: Master/Master Tandem Operation (Tandem Systems Only)

    B position and then executing the START command. Make sure the START command is executed 2 seconds after transmitter-B presses the PITCH pushbutton (refer to the following diagram). Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 49 of 56...
  • Page 50 2 seconds after the PITCH pushbutton is pressed on the other transmitter and then execute the START command. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 50 of 56...

  • Page 51: Master/Slave Tandem Operation (Tandem Systems Only)

    Master transmitter Slave Transmitter Takeover Procedure Rotate to B position Press PITCH Rotate to START → → (After 2 seconds) Master transmitter Master transmitter Slave transmitter Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 51 of 56...

  • Page 52: A/B Pushbutton Select Operation

    2nd operator is unable to take control of the receiver unless the 1st operator presses the “PITCH” pushbutton. See Section 4.2.2.10 on page 35 and Section 4.2.3.2 on page 37 on how to set to this function. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 52 of 56...

  • Page 53: Changing Batteries

    LED off represents no batteries detected. Do not use any rechargeable lithium ion batteries as they will damage both the transmitter and the charging station. Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 53 of 56...

  • Page 54: System Status Light Indications

    STOP button pressed down Solid orange when the power switch key is rotated and hold at the START position Receiver MAIN relays activated at initial system startup Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 54 of 56...

  • Page 55: Receiver Status Indications

    Indication Power to receiver No power to receiver 6.9.4 Receiver COM Indications Type Display Type (Red) Indication Power to relay board No power to relay board Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 55 of 56...

  • Page 56: General Specifications

    260 mm (L) x 204 mm (W) x 83 mm (H) Transmitter Weight: 341 g / 12.0 oz (including batteries) Receiver Weight: 3.15 kg / 6.9 lb (including output cable) Flex 12EX2 Standard, AB and Tandem Instruction Manual November 2017 Page 56 of 56...

This manual is also suitable for:

Flex 12ex2-abFlex 12ex2-t

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