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

Radio control equipment
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Flex 12EX System
Radio Control Equipment
Instruction Manual
0-TC-FLEX12E R4
December 2013
© Copyright 2013 Magnetek Material Handling

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Summary of Contents for Magnetek Flex 12EX System

  • Page 1 Flex 12EX System Radio Control Equipment Instruction Manual 0-TC-FLEX12E R4 December 2013 © Copyright 2013 Magnetek Material Handling...

  • Page 2: Service Information

    Service Information Your New Radio System Thank you for your purchase of Magnetek’s Enrange™ 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 3 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 4: Table Of Contents

    4.2.4.2 Non-Interlocked Functions......................35   4.2.5 Jumper Settings ..........................36   4.2.6 I-CHIP Programming Port ........................ 37   4.2.7 Voltage Settings ..........................37   5. SYSTEM CHANNELS TABLE ........................38   Flex 12EX System Instruction Manual December 2013 Page 4 of 48...
  • Page 5   7.2.4 Receiver POWER Light Indication ....................46   7.2.5 Receiver COM Light Indication ......................46   7.3 TROUBLESHOOTING TIPS ........................47   8. SYSTEM SPECIFICATIONS ......................... 48   Flex 12EX System Instruction Manual December 2013 Page 5 of 48...

  • Page 6: Introduction

    Full compliance – All systems are fully compliant with the FCC Part-15 Rules, European Directives (Safety, EMC, R&TTE, and Machinery), and Industry Canada Specifications (IC). Flex 12EX System Instruction Manual December 2013 Page 6 of 48...

  • Page 7: 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 12EX System Instruction Manual December 2013 Page 7 of 48...

  • Page 8: Critical Installation Considerations

    Flex 12EX System Instruction Manual December 2013 Page 8 of 48...

  • Page 9: Safety Information And Recommended Training For Radio Controlled Equipment Operators

     operate a crane, hoist or lifting device when the device is not centered over the load Flex 12EX System Instruction Manual December 2013 Page 9 of 48...

  • Page 10: Transmitter Unit

    OUT OF SERVICE AND BE REPORTED TO THE SUPERVISOR. 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 11: 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 12: Specific System Warnings

    Make sure the system is not set to the same channel as any other Flex systems in use within a distance of 300 meters (900 feet). Never operate equipment with two transmitter handsets at the same time unless they are programmed to do so. Flex 12EX System Instruction Manual December 2013 Page 12 of 48...

  • Page 13: General System Information

    Push Button #5 Crane Number 5. Push Button #6 Push Button #7 Battery Cover 6. Push Button #8 Push Button #9 FCC Information 7. Push Button #10 Push Button #11 Flex 12EX System Instruction Manual December 2013 Page 13 of 48...

  • Page 14: Internal Illustration

    3.1.2 Internal Illustration (Fig. 03) (Fig. 04) Encoder Board I-CHIP Arial Antenna Function Dip-Switch Transmitting Module Channel Dip-Switch Status LED Display Battery Contact Mechanism Function LED Displays Flex 12EX System Instruction Manual December 2013 Page 14 of 48...

  • Page 15: Receiver Unit

    3.2.1 External Illustration (Fig. 05) Shock Mount COM LED Display Optional External Antenna (BNC) Jack Output Contact Diagram Power LED Display System Information Status LED Display Cord Grip SQ LED Display Flex 12EX System Instruction Manual December 2013 Page 15 of 48...

  • Page 16: Internal Illustration

    3.2.2 Internal Illustration (Fig. 06) AC Line Filter Decoder Module Power Transformer Output Relay Board Receiving Module Flex 12EX System Instruction Manual December 2013 Page 16 of 48...

  • Page 17: Function Settings

    Example: Bottom slot → “0” (Fig. 08) The above dip-switch setting “1 0 0 1 0 0” corresponds to “channel 36” in the system channels table on page 38. Flex 12EX System Instruction Manual December 2013 Page 17 of 48...

  • Page 18: Push Button Functions With Led Display Settings

    Normal Normal LED 1 LED 2 LED 3 LED 4 * PB7…PB12 → Push button number * Normal → Normal momentary contact * LED 1…LED 4 → Transmitter toggled with designated LED Display Flex 12EX System Instruction Manual December 2013 Page 18 of 48...

  • Page 19: Standard Push Button Configuration (A/B Selector)

    D/1&2 D/3&4 Normal Normal Normal Normal * PB7…PB12 → Push button 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) Flex 12EX System Instruction Manual December 2013 Page 19 of 48...
  • Page 20 Normal Normal D/1&2 D/3&4 Normal Normal * PB7…PB12 → Push button 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) Flex 12EX System Instruction Manual December 2013 Page 20 of 48...
  • Page 21 Normal Normal Normal Normal D/1&2 D/3&4 * PB7…PB12 → Push button 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) Flex 12EX System Instruction Manual December 2013 Page 21 of 48...

  • Page 22: Inline Push Button Configuration (Transmitter Toggle)

    Normal Normal LED 1 LED 2 LED 3 LED 4 * PB7…PB12 → Push button number * Normal → Normal momentary contact * LED 1…LED 4 → Transmitter toggled with designated LED Display Flex 12EX System Instruction Manual December 2013 Page 22 of 48...

  • Page 23: Inline Push Button Configuration (A/B Selector)

    Normal Normal * PB7…PB12 → Push button 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) Flex 12EX System Instruction Manual December 2013 Page 23 of 48...
  • Page 24 D/3&4 Normal * PB7…PB12 → Push button 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) Flex 12EX System Instruction Manual December 2013 Page 24 of 48...
  • Page 25 D/1&2 D/3&4 * PB7…PB12 → Push button 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) Flex 12EX System Instruction Manual December 2013 Page 25 of 48...

  • Page 26: Channel Change Via Push Buttons

    CHANNEL dip-switch. Please note that when channel is set beyond channel 62 via PB1 and PB2 (i.e. channel 63, 68, 88, etc…), the system will recognize it as channel 62. Flex 12EX System Instruction Manual December 2013 Page 26 of 48...

  • Page 27: Optional 4-Digit Security Code

    (security code function disabled). If you do not remember the 4-digit security code, then you must contact your dealer or distributor for further assistance. Flex 12EX System Instruction Manual December 2013 Page 27 of 48...

  • Page 28: I-Chip

    37 on how to program the I-CHIP (serial number/ID code) via receiver unit; or 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. (Fig. 11) Flex 12EX System Instruction Manual December 2013 Page 28 of 48...

  • Page 29: Receiver Unit

    Example: Bottom slot → “0” (Fig. 13) The above dip-switch setting “1 0 0 1 0 0” corresponds to “channel 36” in the system channels table on page 38. Flex 12EX System Instruction Manual December 2013 Page 29 of 48...

  • Page 30: Output Relay Configurations

    (F/R2) output relays are closed (refer to page 34 on how to set to this function). Forward 1 speed push button pressed Forward 2 speed push button pressed ↓ ↓ F/R2 F/R2 Flex 12EX System Instruction Manual December 2013 Page 30 of 48...

  • Page 31: On/Off Push Button Function

    ON & OFF rocker switch (refer to page 34 on how to set to this function). When “On” output relay is closed (“On” push button pressed), the “Off” output relay will open automatically, or vice versa. Flex 12EX System Instruction Manual December 2013 Page 31 of 48...

  • Page 32: Start/Aux Function

    (with “UP” push button still hold at 2 speed) will toggle between the 2 speed and 3 speed (refer to page 35 on how to set to this function). SPEED Flex 12EX System Instruction Manual December 2013 Page 32 of 48...

  • Page 33: Auxiliary Stop Push Button Function

    If the first 6 dip-switch positions on the receiving module is set to Ch.01 (“000000” or “000001”), when set to 2-channel scanning (type-3 above), then the receiver will only scan Ch.01 and Ch.02. Flex 12EX System Instruction Manual December 2013 Page 33 of 48...

  • Page 34: Dip-Switch Settings

    FWD/REV toggled (latched) and affected by the E-stop 0001011 command. 0000111 Safety Magnet On & Off 0100001 Closed/Closed + Brake 0100010 Closed/Closed Relay Action + Brake 0100011 Opened/Closed Relay Action + Brake Flex 12EX System Instruction Manual December 2013 Page 34 of 48...

  • Page 35: Non-Interlocked Functions

    Ch.02. Furthermore, you must also set the dip-switch on the receiving module (position #7 & #8) to “10” position (2-channel scanning), please refer to page 33. Flex 12EX System Instruction Manual December 2013 Page 35 of 48...

  • Page 36: Jumper Settings

    Program system serial number/ID code and channel from decoder modul (Blank) to I-CHIP. Program system serial number/ID code and channel from I-CHIP (Inserted) to decoder module. For system test only, receiver MAIN disabled. (Inserted) Flex 12EX System Instruction Manual December 2013 Page 36 of 48...

  • Page 37: I-Chip Programming Port

    0.5A (blue) 3.0A (yellow) 2.0A (purple) 2.0A (purple) 1.0A (red) 1.0A (red) 1.0A (red) 0.5A (blue) 3.0A (yellow) 2.0A (purple) 2.0A (purple) * Output relay fuse → 5.0A (clear) Flex 12EX System Instruction Manual December 2013 Page 37 of 48...

  • Page 38: System Channels Table

    111100 433.700MHZ 011101 434.500MHZ 111101 433.725MHZ 011110 434.525MHZ 111110 I-CHIP 433.750MHZ 011111 111111* * When set to all “1” the priority goes to the channel assigned inside the I-CHIP. Flex 12EX System Instruction Manual December 2013 Page 38 of 48...

  • Page 39: Flex 12Ex System Instruction Manual December

    For F9 and F10 power fuse ratings please refer to page 37. For 12 - 24VDC power supply, wire #1 corresponds to the negative charge (-) and wire #3 corresponds to the positive charge (+). Wire #2 is for GROUND. Flex 12EX System Instruction Manual December 2013 Page 39 of 48...

  • Page 40: Pre-Installation Precautions

    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 variable frequency drive as possible. Flex 12EX System Instruction Manual December 2013 Page 40 of 48...

  • Page 41: System Testing

    3. Test the limit switches (if any) to see if they are working properly. 4. If your new remote control is replacing an existing pendant, make sure it is completely disconnected and placed in a safe location to prevent unwanted control commands. Flex 12EX System Instruction Manual December 2013 Page 41 of 48...

  • Page 42: Operating Procedure

    “Start” position for up to 2 seconds. This will activate the receiver MAIN (depends on JP3 setting on page 36). Thereafter, the same “Start” position will become an auxiliary function with momentary contact (refer to page 32). Flex 12EX System Instruction Manual December 2013 Page 42 of 48...

  • Page 43: A/B Selector Push Button Operating Procedure

    Speed push button one time will activate the 3 speed output relay (toggled). If the operator wants 2 speed again, just press the 3 Speed push button one more time. SPEED Flex 12EX System Instruction Manual December 2013 Page 43 of 48...

  • Page 44: Pitch & Catch Operating Procedure

    After changing the batteries also make sure that all screws are tightened to avoid water, moisture, dirt, grease, or other liquid penetration. (Fig. 20) ↓ Flex 12EX System Instruction Manual December 2013 Page 44 of 48...

  • Page 45: Status Light Indicators & Warnings

    (prior to initiating the START function). Blinking green Pushbutton pressed, signal transmitted. Stop command initiated with receiver Slow red blinks MAIN deactivated. 1 orange blink every 4 seconds Transmitter on standby. Flex 12EX System Instruction Manual December 2013 Page 45 of 48...

  • Page 46: Receiver Status Light Indication

    Display Type Indication (Red) Power to receiver No power to receiver 7.2.5 Receiver COM Light Indication Type Display Type Indication (Red) Power to relay Board No power to relay board Flex 12EX System Instruction Manual December 2013 Page 46 of 48...

  • Page 47: Troubleshooting Tips

    Outputs do not Check the system wiring again. Please refer to correspond to Incorrect output connection the output contact diagram inside this manual or transmitter on the receiver cover. Flex 12EX System Instruction Manual December 2013 Page 47 of 48...

  • Page 48: System Specifications

    Transmitter Dimension 230mm (L) x 69.0mm (W) x 35mm (H) Receiver Dimension 363mm (L) x 228mm (W) x 70mm (H) Transmitter Weight 296g / 10.4oz Receiver Weight 2.5kg / 5.5lb Flex 12EX System Instruction Manual December 2013 Page 48 of 48...

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