Magnetek Flex EM HazLoc Instruction Manual
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Magnetek Flex EM HazLoc Instruction Manual

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Flex EM/EX HazLoc System
Radio Control Equipment
Instruction Manual
Part Number: 191-90002-M0090F R01
June 2019
©Copyright 2019 Magnetek Material Handling

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Summary of Contents for Magnetek Flex EM HazLoc

  • Page 1 Flex EM/EX HazLoc System Radio Control Equipment Instruction Manual Part Number: 191-90002-M0090F R01 June 2019 ©Copyright 2019 Magnetek Material Handling...
  • Page 2 Page Intentionally Left Blank Flex EM/EX HazLoc System Instruction Manual May 2019 Page 2 of 62...

  • Page 3: Table Of Contents

    Table of Contents Introduction............................6 Product Manual Safety Information ....................7 Warnings and Cautions ........................ 8 Critical Installation Considerations ....................9 General............................9 Persons Authorized to Operate Radio-Controlled Cranes ............9 Safety Information and Recommended Training for Radio-Controlled Equipment Operators ... 10 Transmitter Unit..........................
  • Page 4 7.1.3 A/B Selector Pushbutton Operating Procedure (EX Systems Only) ........55 7.1.4 3rd Speed Pushbutton Operating Procedure (EX Systems Only) ......... 56 7.1.5 Pitch & Catch Operating Procedure (EX Systems Only) ............56 7.1.6 Automatic Channel Scanning Operating Procedure (All Systems) ........56 7.1.7 Changing Transmitter Batteries .....................
  • Page 5 Service Information Your New Radio Remote Control System Thank you for your purchase of Magnetek’s Flex EM/EX 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: 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

    2.3 Safety Information and Recommended Training for Radio-Controlled Equipment Operators Anyone being trained to operate radio-controlled equipment should possess as a minimum the following knowledge and skills before using the radio-controlled equipment. The operator should: • have knowledge of hazards pertaining to equipment operation •...

  • 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: Crane/Lifting Device Specific Warnings

    2.9 Crane/Lifting Device Specific Warnings WARNING All equipment must have a mainline contactor installed and all tracked cranes, hoists, lifting devices and similar equipment must have a brake installed. Failure to follow this warning could result in serious injury or death and damage to equipment. An audible and/or visual warning means must be provided on all remote-controlled equipment as required by code, regulation, or industry standard.

  • Page 14: Specific System Warnings

    2.10 Specific System Warnings Below are some specific operating safety tips that should be strictly followed when operating a Flex EM/EX HazLoc system: • Check the Status LED on the transmitter for any signs of low battery power (see Section 7.2 on page 58).

  • Page 15: General System Information

    3 General System Information 3.1 Transmitter Handset 3.1.1 External Illustration Fig. 1 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...

  • Page 16: Internal Illustration

    3.1.2 Internal Illustration Fig. 2 Encoder Board I-CHIP Aerial Antenna Function Dipswitch Transmitting Module Channel Dipswitch Status LED Display Battery Contact Mechanism Function LED Displays * The Flex 8EM, 8EX, 8EX-AB, and 12EX-AB transmitters will differ slightly 3.1.3 Types of Buttons The Flex EM and Flex EX transmitters are offered in either 8-button or 12-button configurations.

  • Page 17: Receiver Unit

    3.2 Receiver Unit 3.2.1 External Illustration (EX) Fig. 3 Shock Mount COM LED Display External Antenna Jack Output Contact Diagram Power LED Display System Information Status LED Display Cord Grip SQ LED Display Flex EM/EX HazLoc System Instruction Manual June 2019 Page 17 of 62...

  • Page 18: External Illustration (Em)

    3.2.2 External Illustration (EM) Fig. 4 External Antenna Jack COM LED Display Power LED Display Output Contact Diagram Status LED Display Cord Grip SQ LED Display Flex EM/EX HazLoc System Instruction Manual June 2019 Page 18 of 62...

  • Page 19: Internal Illustration (Ex)

    3.2.3 Internal Illustration (EX) Fig. 5 AC Line Filter Decoder Module Power Transformer Output Relay Board Receiving Module Flex EM/EX HazLoc System Instruction Manual June 2019 Page 19 of 62...

  • Page 20: Internal Illustration (Em)

    3.2.4 Internal Illustration (EM) I-CHIP PORT SYSTEM FUNCTIONS TEST Fig. 6 Receiving Module AC Line Filter Board Decoder + Relay Board Power Transformer Flex EM/EX HazLoc System Instruction Manual June 2019 Page 20 of 62...

  • Page 21: Function Settings

    4 Function Settings 4.1 Transmitter Handset 4.1.1 System Channel Settings CHANNEL Fig. 7 Set the transmitter channel by adjusting the channel dipswitch located on the backside of the transmitter encoder board (see Fig. 7). Only the first six (6) positions are used for channel programming (see Fig.

  • Page 22: Pushbutton Functions With Led Displays

    4.1.2 Pushbutton Functions with LED Displays 4.1.2.1 Standard Pushbutton Configuration (Transmitter Toggle) Set the transmitter toggle (latching output relay) function by adjusting the 8-position function dipswitch located on the backside of the transmitter encoder board (see Fig. 9). LED 1 through LED 4 shown inside the shaded boxes in the table below illustrate which LED on the transmitter will illuminate when the designated pushbutton (PB7 - PB12) is pressed.
  • Page 23 12-Button Transmitter: PB10 PB11 PB12* 00000000 Normal Normal Normal Normal Normal Normal 00001001 Normal Normal Normal LED 4 Normal Normal 00001010 Normal Normal LED 3 LED 4 Normal Normal 00001011 Normal LED 2 LED 3 LED 4 Normal Normal 00001100 LED 1 LED 2 LED 3...
  • Page 24 8-Button and 12-Button Transmitters: PB8* 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...
  • Page 25 PB8* 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...
  • Page 26 PB8* PB10 PB11 PB12* 01011011 Normal Normal Normal Normal A/1&2 A/3&4 01011100 Normal Normal Normal Normal A/1&2 B/3&4 01011101 Normal Normal Normal Normal A/1&2 C/3&4 01011110 Normal Normal Normal Normal A/1&2 D/3&4 01011111 Normal Normal Normal Normal B/1&2 B/3&4 01100000 Normal Normal Normal...
  • Page 27 8-Button Transmitter: PB8* 00000000 Normal Normal Normal Normal 00000101 Normal Normal Normal LED 4 00010100 Normal Normal LED 3 LED 4 00010101 Normal LED 2 LED 3 LED 4 00010110 LED 1 LED 2 LED 3 LED 4 NOTE: PB8 is not available on A/B transmitters PB5…PB8 →...
  • Page 28 4.1.2.4 Inline Pushbutton Configuration (A/B Selector) (EX Transmitter Only) 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… → →...
  • Page 29 12-Button Transmitter: 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 30 PB10 PB11 PB12* 10000101 Normal A/1&2 A/3&4 Normal 10000110 Normal A/1&2 B/3&4 Normal 10000111 Normal A/1&2 C/3&4 Normal 10001000 Normal A/1&2 D/3&4 Normal 10001001 Normal B/1&2 B/3&4 Normal 10001010 Normal B/1&2 C/3&4 Normal 10001011 Normal B/1&2 D/3&4 Normal 10001100 Normal C/1&2 C/3&4 Normal...

  • Page 31: Channel Change Via Pushbuttons

    PB10 PB11 PB12* 10011010 Normal Normal C/1&2 C/3&4 10011011 Normal Normal C/1&2 D/3&4 10011100 Normal Normal D/1&2 D/3&4 NOTE: PB12 is not available on A/B transmitters PB7…PB12 → Pushbutton number Normal → Normal momentary contact A/1&2…D/3&4 → A/B Selector type with designated LED Display (LED 1&2 or LED 3&4) 4.1.3 Channel Change via Pushbuttons Other than the CHANNEL dipswitch on the encoder board, the transmitter channel can...

  • Page 32: Optional 4-Digit Security Code

    3. When finished, the newly selected channel will appear on the Status LED via a series of green and red blinks again. 4. Exit the channel programming by turning off the transmitter power. 5. Make sure the receiver channel is set identical to the transmitter. See Section 4.2.1 on page 34 and Section 4.2.3 on page 38 on how to change the receiver channel.

  • Page 33: I-Chip

    Steps: Press and hold PB1 - PB4 and rotate the power key to the START position → solid orange → press PB1 four times (for new systems) or 4-digit security code → slow orange blinks → enter the new 4-digit security code → fast orange blinks → re-enter the same 4-digit security code →...

  • Page 34: Receiver Unit

    4.2 Receiver Unit 4.2.1 System Channel Settings Fig. 11 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 38 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 35: Output Relay Configurations

    4.2.2 Output Relay Configurations 4.2.2.1 Output Relay Types (EX System only) NOTE: The following relay types are not available with Flex EM systems. 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).
  • Page 36 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 37 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 39 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 38: Receiver Auto-Scanning Settings

    4.2.2.10 Pitch & Catch Function (EX System only) 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 39 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 39: Dipswitch Settings

    4.2.4 Dipswitch Settings 4.2.4.1 Interlocked Functions for EM Systems Interlocked means the two adjacent pushbuttons cannot be activated simultaneously as they will cancel each other out. Interlocked settings usually apply to a crane’s forward and reverse motions. Each dipswitch on the decoder/relay board corresponds to four (4) pushbuttons on the transmitter handset or four (4) output relays on the decoder/relay board (see Fig.
  • Page 40 4.2.4.2 Interlocked Functions for EX Systems Each dipswitch on the decoder module corresponds to one (1) motion or two (2) adjacent pushbuttons (see Fig. 15 and Fig. 16). Only the first seven (7) dipswitch positions are used (counting from left to right). The 8th dipswitch position (far right) is not used.
  • Page 41 # of Relays Function Descriptions Settings Used 0100010 Closed/Closed Relay Action + Brake 0100011 Opened/Closed Relay Action + Brake 4.2.4.3 Non-Interlocked Functions for EM Systems Unlike interlocked settings, non-interlocked settings allow the two adjacent pushbuttons to be used simultaneously. Function Descriptions # of Relays Settings (left button/right button)
  • Page 42 4.2.4.4 Non-Interlocked Functions for EX Systems Dip Position Setting Function Position #2 - #4 (left button) and Function Description Code Setting #5 - #7 (right button) Normal (momentary) contact Toggled (latching) contact Acceleration (3rd speed) Toggled (latching) contact affected by the E-Stop com- mand.

  • Page 43: Jumper Settings

    4.2.5 Jumper Settings Jumper settings are applied to functions such as mainline-disconnect time, Start function, transmitter pushbutton layout, system information (serial number/ID code) programming, and system testing. For an EM system, jumpers #1 - #7 are located on the decoder/relay board between the receiving RF module and the output relays (see Fig.
  • Page 44 Manufacture preset Jumper Settings Function Receiver MAIN remains closed until the transmitter power (Blank) (Blank) is turned off or emergency stop command is initiated Receiver MAIN opens after 5 minutes of system inactivity (Inserted) (Blank) Receiver MAIN opens after 30 minutes of system inactivity (Blank) (Inserted) Receiver MAIN opens after 60 minutes of system inactivity...

  • Page 45: I-Chip Programming Port

    4.2.6 I-CHIP Programming Port I-CHIP PORT PB9~PB12 SYSTEM FUNCTIONS TEST Fig. 19 Fig. 20 Refer to the I-CHIP PROCEDURE within the Enrange Flex EM/EX/Pro Transmitter ATEX/IECEx Information sheet (198-80210-0010). The I-CHIP programming port located on the decoder module (see Fig. 19 for EM and Fig.

  • Page 46: Voltage Settings

    4.2.7 Voltage Settings Always check that the voltage setting is correct for your application prior to installation (see Fig. 21). NOTE: Fig. 21 and Positions 1-4 below apply only to the EX. Fig. 21 Position 1 110 - 120VAC → Position 2 220 - 240VAC or 24VAC* →...

  • Page 47: 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 48: Receiver Installation

    6 Receiver Installation 6.1 Flex 12EM Output Relay Contact Diagram Pushbutton 1~4 Pushbutton 5~8 Pushbutton 9~12 F1(5A) F2(5A) F3(5A) COM 1 COM 2 COM 3 PB10 PB11 PB12 MAIN Function Power COM 7 FUNC Power K27(NC) MAIN Transformer F8(5A) COM 8 K27(NO) MAIN •...

  • Page 49: Flex 12Ex Output Relay Contact Diagram

    6.2 Flex 12EX Output Relay Contact Diagram • The Flex 8EX will not have pushbuttons 9 - 10 or 11 - 12 (relays K17 - K24; wires 29 - 38). • For Flex 8EX-A/B Systems, A connects to wire #26 and B connects to wire #28. •...

  • Page 50: Pre-Installation Precautions

    6.3 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 51 Fig. 23: Flex EX Flex EM/EX HazLoc System Instruction Manual June 2019 Page 51 of 62...
  • Page 52 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 53: System Testing

    6. On a Flex EM system: Drill one hole (8 mm in diameter) on the control panel or location where the receiver is to be installed. 7. On a Flex EX system: Drill two holes (15 mm in diameter) on the control panel or location where the receiver is to be installed.

  • Page 54: 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 55: Rotary Select A/B Operating Procedure (A/B Systems Only)

    5. Now press any pushbutton on the transmitter handset to operate the crane or equipment. During transmitter inactivity (pushbuttons not pressed), the transmitter will automatically switch to standby mode, with an orange blink on the Status LED at every 4-second interval.

  • Page 56: 3Rd Speed Pushbutton Operating Procedure (Ex Systems Only)

    7.1.4 3rd Speed Pushbutton Operating Procedure (EX Systems Only) When a pushbutton is held at 2nd speed, pressing the 3rd Speed pushbutton one time will activate the 3rd speed output relay (toggled). If SPEED the operator wants 2nd speed again, press the 3rd Speed pushbutton one more time.

  • Page 57: Changing Transmitter Batteries

    7.1.7 Changing Transmitter Batteries Refer to the Enrange Flex EM/EX/Pro Transmitter ATEX/IECEx Information sheet (198-80210-0010) for a list of batteries approved for use with the Flex HazLoc system. Change the transmitter batteries by unscrewing the battery cover located on the backside of the transmitter (see Fig.

  • Page 58: 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 shuts off. Turn the power off to disengage the receiver main.

  • Page 59: 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 60: Troubleshooting Tips

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

  • Page 61: 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 62: 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), ATEX II Direc ve (2014/34/EU), Machinery Safety Direc ve (MD, 2006/42/EC), Radio Equipment Direc ve (RED, 2014/53/EU), EMC Direc ve (2014/30/EU), and the ROHS2 Direc ve (2011/65/EU).

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