Magnetek Flex 12EX Instruction Manual
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Magnetek Flex 12EX Instruction Manual

Radio control equipment, eu systems
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Flex 8EX and 12EX EU Systems
Radio Control Equipment
Instruction Manual
Part Number: 191-90100-3201_R00
March 2018
©Copyright 2018 Magnetek Material Handling

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Summary of Contents for Magnetek Flex 12EX

  • Page 1 Flex 8EX and 12EX EU Systems Radio Control Equipment Instruction Manual Part Number: 191-90100-3201_R00 March 2018 ©Copyright 2018 Magnetek Material Handling...
  • Page 2 Page Intentionally Left Blank Flex 8EX / 12EX EU System Instruction Manual March 2018 Page 2 of 66...

  • Page 3: Table Of Contents

    System Channels Table ........................52 Receiver Installation......................... 53 Output Relay Contact Diagrams....................53 6.1.1 Flex 8EX ..........................53 6.1.2 Flex 12EX ..........................54 Pre-installation Precautions......................55 Flex 8EX / 12EX EU System Instruction Manual March 2018 Page 3 of 66...
  • Page 4 Step-by-Step Installation ......................55 System Testing........................... 57 Operating Procedure ........................58 Transmitter Operation ........................ 58 7.1.1 General Operating Procedure....................58 7.1.2 Rotary Select A/B Operating Procedure ................59 7.1.3 A/B Selector Pushbutton Operating Procedure ..............60 7.1.4 3rd Speed Pushbutton Operating Procedure................. 60 7.1.5 Pitch &...

  • Page 5: Service Information

    Service Information Your New Radio System Thank you for your purchase of Magnetek's Flex EX radio remote control system. Without a doubt, our Flex EX system is the ultimate solution for providing precise, undeterred, and safe control of your material.

  • Page 6: Introduction

    1 Introduction The Flex radio remote control systems are designed for control of industrial equipment and machinery such as overhead traveling cranes, jib cranes, gantry cranes, tower cranes, electric hoists, winches, monorails, conveyor belts, mining equipment and other material handling equipment where wireless control is preferred.

  • Page 7: Product Manual Safety Information

    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 employer to make its employees aware of all of the above listed requirements and to make certain that all operators are properly trained.

  • Page 8: Warnings And Cautions

    1.2 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 WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 9: Critical Installation Considerations

    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.

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

    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 that may cause them to lose control of the equipment, is taking any medication that may cause loss of equipment control, or is under the influence of alcohol or drugs.

  • 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: Batteries

    Do not attempt to open the battery pack. Do not short-circuit the battery. For intrinsically safe environments, only use specified Magnetek intrinsically safe batteries. Keep the battery pack environment cool during charging operation and storage (i.e., not in direct sunlight or close to a heating source).

  • Page 13: Specific System Warnings13

    2.10 Specific System Warnings Below are some specific operating safety tips that should be strictly followed when operating a Flex EX system: • Check the Status LED on the transmitter for any signs of low battery power (see Section 7.2 on page 62).

  • Page 14: General System Information

    3 General System Information 3.1 Transmitter 3.1.1 External Illustration Fig. 1: Flex 8EX Emergency Stop Button Pushbutton #5 Removable Power Key Switch Pushbutton #7 Pushbutton #2 Strap Ring Pushbutton #4 System Information Pushbutton #6 System Channel Pushbutton #8 Crane Number Pushbutton #1 Battery Cover Pushbutton #3...
  • Page 15 Fig. 2: Flex 12EX Emergency Stop Button Pushbutton #5 Removable Power Key Switch Pushbutton #7 Pushbutton #2 Pushbutton #9 Pushbutton #4 Pushbutton #11 Pushbutton #6 Strap Ring Pushbutton #8 System Information Pushbutton #10 System Channel Pushbutton #12 Crane Number Pushbutton #1...

  • Page 16: Internal Illustration

    3.1.2 Internal Illustration Fig. 3: Flex 8EX Encoder Board I-CHIP Aerial Antenna Function Dipswitch Transmitting Module Channel Dipswitch Status LED Display Battery Contact Mechanism Function LED Displays Flex 8EX / 12EX EU System Instruction Manual March 2018 Page 16 of 66...
  • Page 17 Fig. 4: Flex 12EX Encoder Board I-CHIP Aerial Antenna Function Dipswitch Transmitting Module Channel Dipswitch Status LED Display Battery Contact Mechanism Function LED Displays Flex 8EX / 12EX EU System Instruction Manual March 2018 Page 17 of 66...

  • Page 18: Transmitter Handset (A/B)

    3.2 Transmitter Handset (A/B) 3.2.1 External Illustration Fig. 5: Flex 8EX Emergency Stop Button Pushbutton #5 Removable Power Key Switch Pushbutton #7 Pushbutton #2 Strap Ring Pushbutton #4 System Information Pushbutton #6 System Channel Select A, B, A+B Rotary Switch Crane Number Pushbutton #1 Battery Cover...
  • Page 19 Fig. 6: Flex 12EX Emergency Stop Button Pushbutton #5 Removable Power Key Switch Pushbutton #7 Pushbutton #2 Pushbutton #9 Pushbutton #4 Pushbutton #11 Pushbutton #6 Strap Ring Pushbutton #8 System Information Pushbutton #10 System Channel Select A, B, A+B Rotary Switch...

  • Page 20: Internal Illustration

    3.2.2 Internal Illustration Fig. 7: Flex 8EX Encoder Board I-CHIP Aerial Antenna Function Dipswitch Transmitting Module Channel Dipswitch Status LED Display Battery Contact Mechanism Function LED Displays Flex 8EX / 12EX EU System Instruction Manual March 2018 Page 20 of 66...
  • Page 21 Fig. 8: Flex 12EX Encoder Board I-CHIP Aerial Antenna Function Dipswitch Transmitting Module Channel Dipswitch Status LED Display Battery Contact Mechanism Function LED Displays Flex 8EX / 12EX EU System Instruction Manual March 2018 Page 21 of 66...

  • Page 22: Receiver Unit

    3.3 Receiver Unit 3.3.1 External Illustration Fig. 9 Shock Mount COM LED Display Optional External Antenna Jack Output Contact Diagram Power LED Display System Information Status LED Display Cord Grip SQ LED Display Flex 8EX / 12EX EU System Instruction Manual March 2018 Page 22 of 66...

  • Page 23: Internal Illustration

    3.3.2 Internal Illustration Fig. 10 AC Line Filter Decoder Module Power Transformer Output Relay Board Receiving Module Flex 8EX / 12EX EU System Instruction Manual March 2018 Page 23 of 66...

  • Page 24: Function Settings

    4 Function Settings 4.1 Transmitter Handset 4.1.1 System Channel Settings CHANNEL Fig. 11 Set the transmitter channel by adjusting the channel dipswitch located on the backside of the transmitter encoder board (see Fig. 11). Only the first six (6) positions are used for channel programming (see Fig.

  • Page 25: Continuous Transmitting Time Adjustment

    4.1.2 Continuous Transmitting Time Adjustment After the pushbutton is released, the transmitter will continue to transmit neutral signals to the receiver for up to 1 minute. After 1 minute the transmitter will cease transmission, thus temporarily disconnecting the receiver MAIN. (Type 1) After the pushbutton is released, the transmitter will continue to transmit neutral signals to the receiver...
  • Page 26 For 8EX: PB8* 00000000 Normal Normal Normal Normal 00000101 Normal Normal Normal LED 4 00000110 Normal Normal LED 3 LED 4 00000111 Normal LED 2 LED 3 LED 4 00001000 LED 1 LED 2 LED 3 LED 4 NOTE: *PB8 is not available on the A/B transmitters PB5…PB8 ...
  • Page 27 4.1.3.2 Standard Pushbutton Configuration (A/B Selector) There are four (4) different types of A/B selector sequences available on the Flex system. Choose the one that is most suitable for your application. Type-A selector sequence: A+B A+B…    Type-B selector sequence: Off B…...
  • Page 28 For 12EX: PB10 PB11 PB12* 00101111 A/1&2 Normal Normal Normal Normal Normal 00110000 B/1&2 Normal Normal Normal Normal Normal 00110001 C/1&2 Normal Normal Normal Normal Normal 00110010 D/1&2 Normal Normal Normal Normal Normal 00110011 Normal A/3&4 Normal Normal Normal Normal 00110100 Normal B/3&4...
  • Page 29 PB10 PB11 PB12* 01000001 Normal Normal A/1&2 Normal Normal Normal 01000010 Normal Normal B/1&2 Normal Normal Normal 01000011 Normal Normal C/1&2 Normal Normal Normal 01000100 Normal Normal D/1&2 Normal Normal Normal 01000101 Normal Normal Normal A/3&4 Normal Normal 01000110 Normal Normal Normal B/3&4...
  • Page 30 PB10 PB11 PB12* 01010011 Normal Normal Normal Normal A/1&2 Normal 01010100 Normal Normal Normal Normal B/1&2 Normal 01010101 Normal Normal Normal Normal C/1&2 Normal 01010110 Normal Normal Normal Normal D/1&2 Normal 01010111 Normal Normal Normal Normal Normal A/3&4 01011000 Normal Normal Normal Normal...
  • Page 31 4.1.3.3 Inline Pushbutton Configuration (Transmitter Toggle) The pushbutton arrangement for inline pushbutton setup starts from top to bottom and then from the right column to the left column (see Fig. 14 and Fig. 15). To set the inline pushbutton configuration, see JP4 and JP5 jumper settings in Section 4.2.5 on page 48.
  • Page 32 For 12EX: Fig. 15 PB10 PB11 PB12* 00000000 Normal Normal Normal Normal Normal Normal 00000101 Normal Normal Normal LED 4 Normal Normal 00010100 Normal Normal LED 3 LED 4 Normal Normal 00010101 Normal LED 2 LED 3 LED 4 Normal Normal 00010110 LED 1...
  • Page 33 4.1.3.4 Inline Pushbutton Configuration (A/B Selector) There are four (4) different types of A/B selector sequences available on the Flex system. Choose the one that is most suitable for your application. Type-A selector sequence: A+B A+B…    Type-B selector sequence: Off B…...
  • Page 34 For 12EX: PB10 PB11 PB12* 01110011 A/1&2 Normal Normal Normal 01110100 B/1&2 Normal Normal Normal 01110101 C/1&2 Normal Normal Normal 01110110 D/1&2 Normal Normal Normal 00110011 Normal A/3&4 Normal Normal 00110100 Normal B/3&4 Normal Normal 00110101 Normal C/3&4 Normal Normal 00110110 Normal D/3&4...
  • Page 35 PB10 PB11 PB12* 10000001 Normal A/1&2 Normal Normal 10000010 Normal B/1&2 Normal Normal 10000011 Normal C/1&2 Normal Normal 10000100 Normal D/1&2 Normal Normal 01000101 Normal Normal A/3&4 Normal 01000110 Normal Normal B/3&4 Normal 01000111 Normal Normal C/3&4 Normal 01001000 Normal Normal D/3&4 Normal...
  • Page 36 PB10 PB11 PB12* 10001111 Normal Normal A/1&2 Normal 10010000 Normal Normal B/1&2 Normal 10010001 Normal Normal C/1&2 Normal 10010010 Normal Normal D/1&2 Normal 01010111 Normal Normal Normal A/3&4 01011000 Normal Normal Normal B/3&4 01011001 Normal Normal Normal C/3&4 01011010 Normal Normal Normal D/3&4...

  • Page 37: Channel Change Via Pushbuttons

    4.1.4 Channel Change via Pushbuttons Other than the CHANNEL dipswitch on the encoder board, the transmitter channel can also be changed directly on the pushbuttons. Please refer to the instructions below on how to change the transmitter channel via pushbuttons. 1.

  • Page 38: Optional 4-Digit Security Code

    4.1.5 Optional 4-Digit Security Code The 4-digit security code is an optional feature that can be programmed into the transmitter to allow operation only to those who know the code. If this feature is desired, set up as follows: Prior to rotating the transmitter power key switch to the START position to begin operation, you must first enter a 4-digit security code in order to proceed.

  • Page 39: I-Chip

    2. via an external I-CHIP programmer or duplicator unit available from the factory. Please ask your local dealers for assistance if your system requires serial number/ID code adjustments. Flex 8EX Flex 12EX Fig. 16 Flex 8EX / 12EX EU System Instruction Manual March 2018...

  • Page 40: Receiver Unit

    4.2 Receiver Unit 4.2.1 System Channel Settings Fig. 17 Even though the Flex system is equipped with an automatic channel scanning receiver, the user can also set the receiver channel manually. See Section 4.2.3 on page 44 for information on using the automatic channel scanning receiver. Set the receiver channel by adjusting the channel dipswitch located on the receiver module (see Fig.

  • Page 41: Output Relay Configurations

    4.2.2 Output Relay Configurations 4.2.2.1 Output Relay Types 1. 3 output relays per motion – shared 2nd speed output relay 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.
  • Page 42 2. 4 output relay configuration with Opened/Closed contact at 2nd speed* At 2nd speed, only the 2nd speed (F2 or R2) output relay is closed. Forward 1 speed pushbutton pressed Forward 2 speed pushbutton pressed ↓ ↓ 3. 4 output relay configuration with Closed/Closed contact at 2nd speed* At 2nd speed, both 1st speed (F1 or R1) and 2nd speed (F2 or R2) output relays are closed.
  • Page 43 4.2.2.3 ON/OFF Pushbutton Function The user can set any of the two adjacent pushbuttons on the transmitter to behave like a mechanical ON & OFF rocker switch (see Section 4.2.4 on page 45 on how to set to this function). When the ON output relay is closed (ON pushbutton pressed), the OFF output relay will open automatically, or vice versa.

  • Page 44: Receiver Auto-Scanning Settings

    4.2.2.10 Pitch & Catch Function This function allows two operators to control one crane from opposite ends of a cross or long travel (see Section 4.2.4 on page 45 on how to set to this function). When set to “Pitch & Catch” make sure the 2nd transmitter is set to the next-highest channel (channel X*+1).

  • Page 45: Dipswitch Settings

    Fig. 21). Only the first seven (7) dipswitch positions are used (counting from left to right). The 8th dipswitch position (far right) is not used. Fig. 19 RELAY FUNCTIONS Flex 12EX Fig. 20 RELAY FUNCTIONS Flex 8EX Fig. 21...
  • Page 46 Manufacture preset # of Relays Function Descriptions Settings Used 0000100 Forward and Fast output relays engaged at 2nd speed Forward, Slow, and Fast output relays engaged at 2nd 0000101 speed 0000110 ON (right button) & OFF (left button) ON & OFF - affected by the E-Stop command. When 0001000 E-Stop command is initiated, the OFF relay is activated.
  • Page 47 4.2.4.2 Non-Interlocked Functions Unlike interlocked settings, non-interlocked settings allow the two adjacent pushbuttons to be used simultaneously. Non-interlocked settings are usually applied to a crane’s auxiliary functions such as lights, horns, 3rd speed, auxiliary stop, and Pitch & Catch. Each dipswitch on the decoder module corresponds to one (1) motion or two (2) adjacent pushbuttons (left and right pushbuttons).

  • Page 48: Jumper Settings

    (serial number/ID code) programming, and system testing. Jumpers #1 - #7 are located on the decoder module above the four (4) (for Flex 8EX) and six (6) (for Flex 12EX) dipswitches (see Fig. 22 and Fig. 23).
  • Page 49 Manufacture preset Jumper Settings Function After 1 minute (depending on the Continuous Transmitting Time Adjustment setting in Section 4.1.2 on page 25) of (Blank) transmitter inactivity (MAIN deactivated), press any push- button on the transmitter to reactivate the receiver MAIN. After 1 minute (depending on the Continuous Transmitting Time Adjustment setting in Section 4.1.2 on page 25) of transmitter inactivity (MAIN deactivated), rotate the trans-...

  • Page 50: I-Chip Programming Port

    4.2.6 I-CHIP Programming Port For 8EX: Fig. 24 For 12EX: Fig. 25 The I-CHIP programming port located on the decoder module (see Fig. 24 and Fig. 25) inside the receiver is designed for the purpose of transferring system serial number/ID code either from the I-CHIP to the receiver or vice versa.

  • Page 51: Voltage Settings

    4.2.7 Voltage Settings Always check that the voltage setting is correct for your application prior to installation (see Fig. 26). Fig. 26 Position 1 110 - 120VAC  Position 2 220 - 240VAC or 24VAC*  Position 3 380 - 400VAC or 42VAC* ...

  • Page 52: System Channels Table

    5 System Channels Table Dipswitch Dipswitch Channel Frequency Channel Frequency Setting Setting 433.000MHZ 000000 433.775MHZ 100000 433.000MHZ 000001 433.800MHZ 100001 433.025MHZ 000010 433.825MHZ 100010 433.050MHZ 000011 433.850MHZ 100011 433.075MHZ 000100 433.875MHZ 100100 433.100MHZ 000101 433.900MHZ 100101 433.125MHZ 000110 433.925MHZ 100110 433.150MHZ 000111 433.950MHZ...

  • Page 53: Receiver Installation

    6 Receiver Installation 6.1 Output Relay Contact Diagrams 6.1.1 Flex 8EX Flex 8EX / 12EX EU System Instruction Manual March 2018 Page 53 of 66...

  • Page 54: Flex 12Ex

    6.1.2 Flex 12EX • For Flex A/B Systems, A connects to wire #26 (Flex 8EX) and wire #36 (Flex 12EX) and B connects to wire #28 (Flex 8EX) and wire #38 (Flex 12EX). • For 3-relay (shared 2nd speed) and 4-relay (separate 2nd speed) configuration, see Section 4.2.2.1 on page 41.

  • Page 55: Pre-Installation Precautions

    6.2 Pre-installation Precautions 1. Make sure the transmitter and the receiver have identical serial number/ID codes and channels. 2. Make sure the receiver is not set to the same channel as any other systems in use in the surrounding area. 3.
  • Page 56 1. For best reception, the location of the receiver should be visible to the operator at all times. 2. The location selected should not be exposed to high levels of electric noise. Mounting the receiver next to an unshielded variable-frequency drive may cause minor interference. Always locate the receiver as far away from a variable-frequency drive as possible.

  • Page 57: System Testing

    6.4 System Testing 1. Turn on the power source to the receiver and test the MAIN relay output by pressing the red emergency stop button and observe that it properly opens and closes the mainline disconnect contactor. 2. Test the operation of each function to ensure it corresponds to the transmitter direction labels or the pendant it is replacing.

  • Page 58: Operating Procedure

    7 Operating Procedure 7.1 Transmitter Operation 7.1.1 General Operating Procedure 1. Reset the red emergency stop button located on the top left side of the transmitter handset by rotating it either clockwise or counterclockwise. The red button will pop up. 2.

  • Page 59: Rotary Select A/B Operating Procedure

    5. In case of an emergency, pressing down the red emergency stop button will immediately disconnect the receiver MAIN as well as the transmitter power. To resume operation, rotate the red button clockwise or counterclockwise until it pops up. Then, rotate the power key switch to the START position for up to 2 seconds to resume operation (depending on JP3 setting;...

  • Page 60: A/B Selector Pushbutton Operating Procedure

    7.1.3 A/B Selector Pushbutton Operating Procedure Pressing the “Select A/B” pushbutton will toggle between output relay A, B, and A+B, respectively. There are 4 different types of Select A/B sequences available; see Section 4.1.3.2 on page 27 for instructions on how to set Select A/B functions. 7.1.4 3rd Speed Pushbutton Operating Procedure When a pushbutton is held at 2nd speed,...

  • Page 61: Changing Transmitter Batteries

    7.1.7 Changing Transmitter Batteries Change the transmitter batteries by unscrewing the battery cover located on the backside of the transmitter (see Fig. 30). During battery installation, make sure that the blue ribbon is centered between the two batteries. After changing the batteries, also make sure that all screws are tightened to avoid water, moisture, dirt, grease, or other liquid penetration.

  • Page 62: Status Light Indicators And Warnings

    7.2 Status Light Indicators and Warnings 7.2.1 Transmitter STATUS Light Indication Type Display Type Indication Voltage goes below 1.9V at initial power on - transmitter power shuts off. Solid red Voltage goes below 1.8V during operation - transmitter power and receiver MAIN shut off.

  • Page 63: Receiver Status Light Indication

    7.2.2 Receiver STATUS Light Indication Type Display Type Indication Fast green blinks Decoding in process Slow green blinks Decoding on standby Stop command initiated with Slow red blinks receiver MAIN deactivated Receiver MAIN jammed or 2 red blinks defective Incorrect transmitter serial Fast red blinks number/ID code Receiver under-voltage, LV...

  • Page 64: Troubleshooting Tips

    7.3 Troubleshooting Tips Problems Possible Reasons Suggestions Transmitter low Check the transmitter battery level. battery power Emergency stop Prior to turning on the transmitter button activated prior power switch, make sure the red to startup emergency stop button is elevated. Redo the startup procedure by holding Improper startup pro- the power key at the START position...

  • Page 65: System Specifications

    8 System Specifications Frequency Range: 433 - 434 MHz Frequency Deviation: 12.5 KHz Number of Channels: 62 channels Modulation: Digital Frequency Modulation based on Manchester Code, 20-bit address, 32-bit CRC Parity Check and Hamming Code. Encoder & Decoder: Microprocessor-controlled Transmitting Range: >100 meters (300 feet) Frequency Control: Synthesized PLL (Phase Lock Loop)

  • Page 66: Declaration Of Conformity

    Menomonee Falls, WI 53051 The undersigned hereby declares on behalf of Magnetek, that the above-referenced products, to which this declara on relates, is in conformity with the provisions of CE Mark Direc ve (93/68/EEC), Machinery Safety Direc ve (MD) 2006/42/EC, and Radio Equipment Direc ve (RE-D) 1999/5/EC.

This manual is also suitable for:

Flex 8exFlex 4exFlex 6ex

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