Flex 4EM System Radio Control Equipment Instruction
Contents
1. ERRAAHEE _ Example Top slot 1 Bott lot 0 E an un ottom sio Fig 11 123456 HEHEHEHEH The above dip switch setting 1 0 0 1 0 0 corresponds to channel 36 in the system channels table on page 22 Flex 4EM System Instruction Manual November 2010 17 of 31 2 Receiver Auto Scanning Settings Receiver Channel Dip switch HRARARER gt Scanning all 62 channels manufacture preset For standard operation 1 78 BEBBBEEBE ay pe LEGE Single fixed channel a Auto scanning function disabled 78 3 RABE oe Scanning 2 channels only mo urn oo urn oo ur mo urn Em ur Scanning 3 channels only A m m M e NE ci HBEEBHBBEH 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 4EM System Instruction Manual November 2010 18 of 31 3 Dip Switch Settings Each dip switch dip position 1 8 on the decoder relay board corresponds to four 4 push buttons on the transmitter handset or four 4 output relays on the decoder relay board i e dip position 1 4 corresponds to PB1 amp 2 on the transmitter handset or K1 amp 2 on the decoder relay board and dip position 5 8 corresponds to PB3 amp 4 on the transmitter handset or K3 amp 4 on2. Incorrect wiring Check input voltage connection Check the system wiring again Please refer to Outputs do not correspond to Incorrect output connection transmitter the output contact diagram inside this manual or on the receiver cover Flex 4EM System Instruction Manual November 2010 30 of 31 8 System Specifications Frequency Range Frequency Deviation Number of Channels Modulation Encoder amp Decoder Transmitting Range Frequency Control Receiver Type Receiver Sensitivity Spurious Emission Antenna Impedance Responding Time Transmitting Power Enclosure Type Enclosure Rating Output Contact Rating Transmitter Operating Voltage Receiver Power Consumption Receiver Supply Voltage Operating Temperature Transmitter Dimension Receiver Dimension Transmitter Weight Receiver Weight 433 434 MHz 12 5 KHz 62 channels Digital Frequency Modulation based on Manchester Code 20bit address 32bit CRC Parity Check and Hamming Code Microprocessor controlled 2100 Meters 300 Feet Synthesized PLL Phase Lock Loop Frequency Auto Scanning 116dBm 50dB 50 ohms 60 Milliseconds average 1 0mW NEMA 4 IP 66 250V 8 Amps DC 3 0V 7 0 VA Voltage Setting Min Max 24VAC 22 26VAC 42VAC 38 46VAC 48VAC 43 53VAC 110VAC 104 126VAC 220VAC 207 253VAC 380VAC 351 429VAC 410VA 400 480VAC 12 24VDC 9 36VDC 25 C 75 C 13
3. Flex 4EM System Radio Control Equipment Instruction Manual MAGNETEK MATERIAL HANDLING ENRANGE 0 FLEX 4EM ME November 2010 Copyright 2010 Magnetek Material Handling 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 If your product ever needs modification or service please contact one of our representatives at the following locations U S Service Information For questions regarding service or technical information contact 1 866 MAG SERV 1 866 624 7378 Magnetek Material Handling N49 W13650 Campbell Drive Menomonee Falls WI 53051 Telephone 1 800 288 8178 Website www magnetekmh com E mail info magnetekmh com Fax Numbers Main 1 800 298 3503 Sales 1 262 783 3510 Service 1 262 783 3508 Canada Service Information 2610 Dunwin Drive Mississauga Ontario L5L 1J5 Canada Telephone 1 800 792 7253 Fax 1 905 828 5707 PRODUCT MANUAL SAFETY INFORMATION Magnetek Inc Magnetek offers a broad range of radio remote control products control products and adjustable frequency drives and industrial braking systems for material handling applications This manual has been prepared by Magnetek to provide information and recommendations for the installation use operation and service of M
4. HRHRHHRER RE PFFFEEEE o FN v 9 Y Tit CR i m WE ONO AN WAE 7 Fig 04 I CHIP Function Dip Switch not used Channel Dip Switch Battery Contact Mechanism Flex 4EM System Instruction Manual November 2010 10 of 31 B RECEIVER UNIT 1 External Illustration s 2 6 Fig 05 1 External Antenna Jack 5 COM LED Display 2 Power LED Display 6 Output Contact Diagram 3 Status LED Display T Cord Grip 4 SQ LED Display Flex 4EM System Instruction Manual November 2010 11 of 31 2 Internal Illustration ED ED En WEFFESEH D H ce Fig 06 1 Receiving Module 9 AC Line Filter Board 2 Decoder Relay Board 4 Power Transformer Flex 4EM System Instruction Manual November 2010
5. 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 Ig Fig 09 Flex 4EM System Instruction Manual November 2010 16 of 31 B RECEIVER UNIT 1 System Channel Settings M sn fou f n nn pm rm 1 2 2 4 8 6 T B TIRES TE TETE Fig 10 Even though the Flex system is equipped with an automatic channel scanning receiver the user can also set the receiver channel manually Please refer to page 27 on how the automatic channel scanning receiver works Set the receiver channel by adjusting the channel dip switch located on the receiver module refer to Fig 10 above only the first six 6 positions are used for channel programming refer to Fig 11 below The system channels table located on page 22 illustrates which dip switch setting corresponds to which channel Once the receiver channel is altered make sure to change the transmitter channel as well The channel on both the transmitter and receiver must be identical in order for the system to work To change the transmitter channel please refer to page 13
6. Magnetek Products prior to becoming familiar with and being trained in these requirements and the instructions and safety recommendations in this manual WARRANTY INFORMATION FOR INFORMATION ON MAGNETEK S PRODUCT WARRANTIES BY PRODUCT TYPE PLEASE VISIT WWW MAGNETEKMH COM Table of Contents Page 1 Introduction 2 2 Radio Controlled Safety 3 3 General System Information A Transmitter Handset 1 External Illustration 2 Internal Illustration 10 B Receiver Unit 1 External Illustration 11 2 Internal Illustration 12 4 Function Settings A Transmitter Handset 1 System Channel Settings 13 2 Channel Change via Push Buttons 14 3 Optional 4 digit Security Code 15 4 I CHIP 16 B Receiver Unit 1 System Channel Settings 17 2 Receiver Auto Scanning Settings 18 3 Dip Switch Settings 19 4 Jumper Settings 20 5 lCHIP Programming Port 21 6 Fuse Ratings 21 5 System Channels Table 22 6 Receiver Installation A Output Relay Contact Diagram 23 B Pre Installation Precautions 24 C Step by Step Installation 24 D System Testing 25 7 Operating Procedure A Transmitter Operation 1 General Operating Procedure 26 2 Automatic Channel Scanning Operating Procedure 27 3 Changing Transmitter Batteries 27 B Status Light Indicators amp Warnings 1 Transmitter STATUS Light Indication 28 2 Receiver STATUS Light Indication 29 3 Receiver SQ Light Indication 29 4 Receiver POWER Light Indication 29 5 Receiver COM Light Indicati
7. appear on the Status LED showing the current channel setting green blink represents the tens 10 and a red blink represents the units 1 Examples 2 green blinks followed by 5 red blinks represents channel 25 6 red blinks represents channel 06 ON gr PB2 PB eee PBS M um Select a new channel by pressing PB1 and PB2 on the transmitter Press PB1 to increment the units 1 and PB2 to increment the tens 10 m mom mmm Om RR oe Examples Press PB2 two times and then PB1 four times will give you channel 24 Press PB1 nine times with give you channel 09 When finished the newly selected channel will appear on the Status LED via a series of green and red blinks again Exit the channel programming by turning off the transmitter power Make sure the receiver channel is set identical to the transmitter Please refer to page 17 and page 27 on how to change receiver channel Please note that when the CHANNEL dip switch inside the transmitter is changed the priority will revert back to the new channel set on the 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 4EM System Instruction Manual November 2010 14 of 31 3 Optional 4 Digit Security Code The 4 digit Security Code is an optional feature that can be programmed into the transmitter to allow operation onl
8. other material handling equipment being operated have knowledge of the use of equipment warning lights and alarms have knowledge of the proper storage space for a radio control transmitter when not in use be trained in transferring a radio control transmitter to another person be trained how and when to report unsafe or unusual operating conditions test the transmitter emergency stop and all warning devices prior to operation testing should be done on each shift without a load be thoroughly trained and knowledgeable in proper and safe operation of the crane hoist lifting device or other material handling equipment that utilizes the radio control know how to keep the operator and other people clear of lifted loads and to avoid pinch points continuously watch and monitor status of lifted loads know and follow cable and hook inspection procedures know and follow the local lockout and tagout procedures when servicing radio controlled equipment know and follow all applicable operating and maintenance manuals safety procedures regulatory requirements and industry standards and codes The operator shall not lift or move more than the rated load operate the material handling equipment if the direction of travel or function engaged does not agree with what is indicated on the controller use the crane hoist or lifting device to lift support or transport people lift or carry any loads over people operate the crane hoist or
9. the decoder relay board refer to Fig 12 amp 13 below LIII LI LII LI LII LI LII LI BRAUN vad lad oo W CIN EE oOo NI amm anc uno ON E unm Fig 12 Fig 13 Interlocking Features Dip Function Descriptions of Relays Settings left button right button Used 0000 Normal Normal 2 0001 On Off 2 0010 Toggled Toggled 2 Manufacture Preset Non Interlocking Features Dip Function Descriptions of Relays Settings left button right button Used 1000 Normal Normal 2 1001 Toggled Normal 2 1010 Normal Toggled 2 1011 Toggled Toggled 2 1100 Toggled shuts off when e stop is pressed Normal 2 1101 Normal Toggled shuts off when e stop is pressed 2 1110 Toggled Toggled both shuts off when e stop is pressed 2 Flex 4EM System Instruction Manual November 2010 19 of 31 4 Jumper Settings Jumper settings are applied to functions such as main disconnect time Start function transmitter push button layout system information serial number ID code programming and system testing Jumpers 1 7 are located on t
10. where the receiver is to be installed refer to Fig 16 on page 24 Make sure the bolt is tightened after installation 28 0 aa For system wiring please refer to page 23 D 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 Test the operation of each function to ensure it corresponds to the transmitter direction labels or the pendant it is replacing Test the limit switches if any to see if they are working properly 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 4EM System Instruction Manual November 2010 25 of 31 7 Operating Procedure A TRANSMITTER OPERATION 1 General Operating Procedure a Reset the red emergency stop button located on the top left hand side of the transmitter handset by rotating it either clockwise or counter clockwise The red button will pop up b Turnon the transmitter power by inserting the black colored key into the power key slot located on the top right hand side of the transmitter handset and rotate it clockwise to On position c After turning on the transmitter power check the Status LED on the transmitter handset for any sign of system irregularities refer to Status Light I
11. 00111 08 433 175MHZ 001000 40 433 975MHZ 101000 09 433 200MHZ 001001 41 434 000MHZ 101001 10 433 225MHZ 001010 42 434 025MHZ 101010 11 433 250MHZ 001011 43 434 050MHZ 101011 12 433 275MHZ 001100 44 434 075MHZ 101100 13 433 300MHZ 001101 45 434 100MHZ 101101 14 433 325MHZ 001110 46 434 125MHZ 101110 15 433 350MHZ 001111 47 434 150MHZ 101111 16 433 375MHZ 010000 48 434 175MHZ 110000 17 433 400MHZ 010001 49 434 200MHZ 110001 18 433 425MHZ 010010 50 434 225MHZ 110010 19 433 450MHZ 010011 51 434 250MHZ 110011 20 433 475MHZ 010100 52 434 275MHZ 110100 21 433 500MHZ 010101 53 434 300MHZ 110101 22 433 525MHZ 010110 54 434 325MHZ 110110 23 433 550MHZ 010111 55 434 350MHZ 110111 24 433 575MHZ 011000 56 434 375MHZ 111000 25 433 600MHZ 011001 57 434 400MHZ 111001 26 433 625MHZ 011010 58 434 425MHZ 111010 27 433 650MHZ 011011 59 434 450MHZ 111011 28 433 675MHZ 011100 60 434 475MHZ 111100 29 433 700MHZ 011101 61 434 500MHZ 111101 30 433 725MHZ 011110 62 434 525MHZ 111110 31 433 750MHZ 011111 Flex 4EM System Instruction Manual November 2010 22 of 31 6 Receiver Installation A OUTPUT RELAY CONTACT DIAGRAM Push button 1 4 MAINE Function COM 7 K26 FUNC NEN K27 NC MAIN COM 8 K27 NO MAIN F1 5A Power Transformer 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 Wire
12. 12 of 31 4 Function Settings A TRANSMITTER HANDSET 1 System Channel Settings Fig 07 Set the transmitter channel by adjusting the channel dip switch located on the backside of the transmitter encoder board refer to Fig 07 above Only the first six 6 positions are used for channel programming refer to Fig 08 below The system channels table located on page 22 illustrates which dip switch setting corresponds to which channel Once the transmitter channel is altered make sure to change the receiver channel as well The channel on both the transmitter and receiver must be identical in order for the system to work To change the receiver channel please refer to page 17 EHRHBRERHR p Example Top slot 1 E Bottom slot 0 Fig 08 123456 EHEHEHHB The above dip switch setting 1 0 0 1 0 0 corresponds to channel 36 in the system channels table on page 22 Flex 4EM System Instruction Manual November 2010 13 of 31 2 Channel Change via Push Buttons Other than CHANNEL dip switch on the encoder board the transmitter channel can also be changed directly on the push buttons Please refer to the instruction below on how to change the transmitter channel via push buttons a b Press and hold PB1 PB2 and PB3 and rotate the power key to START position at the same time A series of green and red blinks will
13. 6 is for Normal Close and wire 8 is for Normal Open MAIN output Flex 4EM System Instruction Manual November 2010 23 of 31 B PRE INSTALLATION PRECAUTIONS 1 Make sure the transmitter and 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 Make sure that the crane or equipment is working properly prior to 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 C STEP BY STEP INSTALLATION 5 91 23 EL I iN J m i aes CT P 1 Te Fig 16 1 For best reception the location of the receiver should be visible to the operator at all time 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 the variable frequency drive as possible Flex 4EM System Instruction Manual November 2010 24 of 31 Ensure the selected location has adequate space to accommodate the receiver refer to Fig 16 on page 24 For better reception make sure the receiver is in an upright position Drill one hole 8mm in diameter on the control panel or location
14. F 167 F 138mm L x 69mm W x 34mm H 180mm L x 150mm W x 82mm H 192g 6 80z 2 1kg 4 6lb include output cable Flex 4EM System Instruction Manual November 2010 31 of 31
15. LE AND OR VISUAL WARNING DEVICES MUST MEET ALL GOVERNMENTAL REQUIREMENTS FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT FOLLOW YOUR LOCAL LOCKOUT TAGOUT PROCEDURE BEFORE MAINTAINING ANY REMOTE CONTROLLED EQUIPMENT ALWAYS REMOVE ALL ELECTRICAL POWER FROM THE CRANE HOIST LIFTING DEVICE OR SIMILAR EQUIPMENT BEFORE ATTEMPTING ANY INSTALLATION PROCEDURES DE ENERGIZE AND TAGOUT ALL SOURCES OF ELECTRICAL POWER BEFORE TOUCH TESTING ANY EQUIPMENT FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT THE DIRECT OUTPUTS OF THIS PRODUCT ARE NOT DESIGNED TO INTERFACE DIRECTLY TO TWO STATE SAFETY CRITICAL MAINTAINED FUNCTIONS lE MAGNETS VACUUM LIFTS PUMPS EMERGENCY EQUIPMENT ETC A MECHANICALLY LOCKING INTERMEDIATE RELAY SYSTEM WITH SEPARATE POWER CONSIDERATIONS MUST BE PROVIDED FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH OR DAMAGE TO EQUIPMENT 2 2 GENERAL Radio controlled material handling equipment operates in several directions Cranes hoists lifting devices and other material handling equipment can be large and operate at high speeds Quite frequently the equipment is operated in areas where people are working in close proximity to the material handling equipment The operator must exercise extreme caution at all times Workers must constantly be alert to avoid accidents The following recommendations have been included t
16. agnetek 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 material handling equipment which use or include Magnetek Products e Instructions manuals and safety warnings of the manufacturers of the equipment where the radio system is used e Plant safety rules and procedures of the employers and the owners of facilities where the Magnetek Products are being used e Regulations issued by the Occupational Health and Safety Administration OSHA e Applicable local state or federal codes ordinances standards and requirements or e 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 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 No one should use
17. amp WARNINGS 1 Transmitter STATUS Light Indication Type Display Type Indication Voltage goes below 1 9V at initial power on transmitter power shuts off 1 Constant red Voltage goes below 1 8V during operation transmitter power shuts off Turn the power off to disengage the receiver main 2 1 red blink followed by a 2 Voltage goes below 1 85V during operation second pause change batteries immediately 3 2 red blinks followed by a 2 The pushbutton is defective after turning on the second pause transmitter power When a defective push button condition occurs 2 red blinks type 3 above find out which push button is defective by pressing all the push buttons on the transmitter one at a time If the 4 No light displayed n push button is in good working order the LED will not light up when pressed If the push button is defective the LED will continue to display 2 red blinks when pressed 3 red blinks followed by a 2 5 EEPROM error Second pause 6 4 red blinks followed by a 2 Transmitting error system cannot lock on second pause to the designated channel 7 Constant green for up to 2 Transmitter power on with no faults detected seconds prior to initiating the START function 8 Blinking green Pushbutton pressed signal transmitted Stop command initiated with receiver 9 Slow red blinks MAIN deactivated 10 1 orange blink every 4 seconds T
18. f functional effectiveness Cautions are highlighted as shown below CAUTION WARNINGS and CAUTIONS SHOULD NEVER BE DISREGARDED The safety rules in this section are not intended to replace any rules or regulations of any applicable local state or federal governing organizations Always follow your local lockout and tagout procedure when maintaining any radio equipment 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 4EM System Instruction Manual November 2010 3 of 31 2 1 CRITICAL INSTALLATION CONSIDERATIONS AN 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 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 THESE AUDIB
19. f you believe you have entered the correct code but the transmitter fails to work properly then you must reset the transmitter power by power cycling the transmitter and then repeat steps a b and c again Note To power cycle the transmitter you must first remove then reinstall the batteries Simply turning the power switch off then on will NOT properly clear the memory This process must be used for any errors regarding proper transmitter operation not just for security code settings Steps Press and hold PB1 PB4 and rotate power key to START position constant 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 again green light d If you wish to cancel the security code function then repeat steps a b and c above and press PB1 four times as your new security code security code function disabled e If you do not remember the 4 digit security code then you must contact your dealer or distributor for further assistance Flex 4EM System Instruction Manual November 2010 15 of 31 4 I CHIP The I CHIP functions in a way that is very similar to a SIM card inside a mobile phone which stores system information such as your telephone number account number phone book and other settings The I CHIP works exactly the same way as it stores information such as system ser
20. he decoder relay board between the receiving RF module and the output relays refer to Fig 14 below Fig 14 Manufacture preset Jumper Settings Function JP1 JP2 Receiver MAIN remained closed until the transmitter power is turned Blank Blank off or emergency stop command is initiated JP1 JP2 3 um Inserted Blank Receiver MAIN opens after 5 minutes of system inactivity JP1 JP2 M Blank Inserted Receiver MAIN opens after 30 minutes of system inactivity JP1 JP2 Inserted Inserted Receiver MAIN opens after 60 minutes of system inactivity Press any push button on the transmitter to activate the receiver MAIN JPS t syst tart ft t t and aft tem inactivit Blank at system startup after e stop reset and after system inactivity refer to JP1 amp JP2 settings above JP3 Rotate the power key switch to START position to activate the receiver Inserted MAIN at system startup after e stop reset and after system inactivity refer to JP1 amp JP2 settings above JP4 JPS Blank Blank Standard right to left push button configuration for all models JP4 JP5 Inserted Blank In line push button configuration top to bottom for Flex 8EM JP4 JP5 Blank Inserted In li
21. hones with the ability to transfer system information and settings from one transmitter to another without the hassle of resetting the spares Reliable push buttons The in house designed push buttons with gold plated contacts are rated for more than one million press cycles Low power consumption Requires only two AA Alkaline batteries for more than 100 hours of operating time between replacements Ultra durable nylon and fiberglass composite enclosures Highly resistant to breakage and deformation even in the most abusive environments Full compliance All systems are fully compliant with the FCC Part 15 Rules European Directives Safety EMC R amp TTE and Machinery and Industry Canada Specifications IC Flex 4EM System Instruction Manual November 2010 2 of 31 2 Radio Controlled Safety 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 A warning highlights an essential operating or maintenance procedure practice etc which if not strictly observed could result in injury or death of personnel or long term physical hazards Warnings are highlighted as shown below WARNING CAUTION A caution highlights an essential operating or maintenance procedure practice etc which if not strictly observed could result in damage to or destruction of equipment or loss o
22. ial number ID code channel and push button configurations When replacing a transmitter handset just take the I CHIP out of the old transmitter and install it into the new one refer to Fig 09 below For a complete information transfer make sure both the Channel and Function dip switch is set to all 1 If both dip switches are set to all 1 then the transmitter will operate according to the push button configurations and channel stored inside the l CHIP If both the Channel and Function dip switch is set to other values other than all 1 then the transmitter will operate according to the channel and push button configurations set on these two dip switches not the ones stored inside the I CHIP Every time the settings on these two dip switches are changed the new settings will be stored into the I CHIP automatically In this case the previous channel and push button configurations stored inside the I CHIP will be erased and be replaced by the new settings For safety purposes the system serial number ID code stored inside the I CHIP cannot be changed directly on the transmitter encoder board Only channels and push button configurations can be changed directly on the encoder board via Channel and Function dip switches There are only two ways that you can change a transmitter serial number ID code via the I CHIP programming port located on the decoder module inside the receiver unit please refer to page 21 on how to program the
23. igns of irregularities refer to page 28 3 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 4 Never operate equipment with two transmitter handsets at the same time unless they are programmed to do so Flex 4EM System Instruction Manual November 2010 8 of 31 1 3 General System Information A TRANSMITTER HANDSET External Illustration X Y el i i i TUER are N Fig 01 Emergency Stop Button T Removable Power Key Switch 8 Push Button 2 9 Push Button 4 Push Button 1 Push Button 3 OX BSD S EN G Ns u rs 4 f f 4 p W Fig 02 Strap Ring System Information System Channel Crane Number Battery Cover FCC Information Flex 4EM System Instruction Manual November 2010 9 of 31 Internal Illustration t Fig 03 Encoder Board Arial Antenna Transmitting Module Status LED Display Function LED Displays Oo D HRHRBHHHH Oo
24. is activated prior to startup elevated Redo the startup procedure by holding the power Improper startup procedure key at START position for up to 2 0 seconds No response when and then release transmitter push button is pressed Make sure that the transmitter handset and the Improper startup amp Incorrect system RF channel i settings receiver unit both have the same channel Make sure that the transmitter handset and Incorrect system serial receiver unit both have the same serial number ID code number ID code Make sure that the startup procedure is initiated System out of range within 100 meters 300 feet from the receiver location Check the SQ display on the face of the receiver unit If it does not light up when the push button is pressed then either the Defective transmitting and transmitting or receiving module is defective No response when receiving module First replace the transmitting module If SQ transmitter push E display is still not lit when the push button is button is pressed pressed then go ahead and replace the Damaged hardware receiving module If still no response then replace the transmitter Defective encoder encoder board If still doesn t work then the board or decoder module decoder module is defective Incorrect input voltage Make sure the source voltage is set correctly No AC power to Blown fuse Check for any blown fuse the receiver
25. lifting device unless all persons including the operator are and remain clear of the supported load and any potential pinch points operate a crane hoist or lifting device when the device is not centered over the load operate a crane hoist or lifting device if the chain or wire rope is not seated properly in the sprockets drum or sheave operate any damaged or malfunctioning crane hoist lifting device or other material handling equipment Flex 4EM System Instruction Manual November 2010 5 of 31 e change any settings or controls without authorization and proper training e remove or obscure any warning or safety labels or tags e leave any load unattended while lifted e leave power on the radio controlled equipment when the equipment is not in operation e operate any material handling equipment using a damaged controller because the unit may be unsafe e operate manual motions with other than manual power e operate radio controlled equipment when low battery indicator is on WARNING THE OPERATOR SHOULD NOT ATTEMPT TO REPAIR ANY RADIO CONTROLLER IF ANY PRODUCT PERFORMANCE OR SAFETY CONCERNS ARE OBSERVED THE EQUIPMENT SHOULD IMMEDIATELY BE TAKEN 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 2 5 TRANSMITTER UNIT Transmitter
26. mitter power by rotating the power key counter clockwise to Off position it will disconnect the transmitter power and the receiver MAIN altogether Turn it further counter clockwise to release the key Automatic Channel Scanning Operating Procedure After changing the transmitter channel refer to page 13 turn on the transmitter power and rotate the power key switch to Start position and hold it there for up to 1 minute Within this 1 minute period the receiver will search channel 01 channel 62 and lock onto the newly selected transmitter channel automatically Please note that in order for the receiver to switch to auto scanning mode prior to changing the transmitter channel you must first deactivate the receiver MAIN by shutting off the transmitter power or press down the emergency stop button Please refer to page 18 if you do not want the receiver to auto scan all 62 channels Change Transmitter Channel Changing Transmitter Batteries Change the transmitter batteries by unscrewing the battery cover located on the backside of the transmitter refer to Fig 17 below 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 Fig 17 O Flex 4EM System Instruction Manual November 2010 27 of 31 B STATUS LIGHT INDICATORS
27. ndicators amp Warnings on page 28 If the system is normal the Status LED will light up green for two 2 seconds d dfthere are no signs of any system irregularities then rotate the power key further clockwise to Start position for up to 2 seconds This will activate the receiver MAIN depends on JP3 setting on page 20 Thereafter the same Start position will become an auxiliary function outputted via K26 FUNCTION output relay wire 5 Flex 4EM System Instruction Manual November 2010 26 of 31 e Now press any push button on the transmitter handset to operate the crane or equipment During transmitter inactivity push buttons not pressed the transmitter will automatically Switch to standby mode with an orange blink on the Status LED every 4 second interval f In case of an emergency pressing down on the red emergency stop button will immediately disconnect the receiver mainline Status LED blinks red To reset the emergency stop button just rotate the red button either clockwise or counter clockwise it will pop up When the green light appears rotate the power key to Start position to resume operation depends on JP3 setting on page 20 g After 5 minutes of inactivity push button not pressed the receiver MAIN will be disconnected temporarily depends on JP1 amp JP2 settings on page 20 To resume operation just rotate the power key switch to START position to reconnect the receiver MAIN h Turn off the trans
28. ne push button configuration top to bottom for Flex 12EM JP4 JP5 i Inserted Inserted In line push button configuration top to bottom for Flex 4EM JP6 Program system serial number ID code and channel from decoder Blank module to I CHIP JP6 Program system serial number ID code and channel from I CHIP Inserted to decoder module d For system test only receiver MAIN disabled Inserted y y j Flex 4EM System Instruction Manual November 2010 20 of 31 5 I CHIP Programming Port I CHIP PORT Ed T q PPI ae EaR Fig 15 The I CHIP programming port located on the decoder module refer to Fig 15 above inside the receiver is designed for the purpose of transferring system serial number ID code either from l CHIP to receiver or vice versa If you wish to transfer system information from receiver to I CHIP just insert the I CHIP onto the programming port JP6 jumper not inserted wait until the Status LED on the decoder module turned constant green within 2 seconds and then take the I CHIP out of the programming port programming completed At this time the I CHIP should also p
29. nsically safe environments only use specified Magnetek Telemotive 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 2 9 BATTERY CHARGING For those transmitters equipped with battery chargers please familiarize all users with the instructions of the charger before attempting to use Do not attempt to charge non rechargeable battery packs Avoid charging partially discharged rechargeable batteries to help prolong battery cycle life Avoid charging the battery pack for more than 24 hours at a time Do not charge batteries in a hazardous environment Do not short the charger Do not attempt to charge a damaged battery Use only Magnetek Telemotive approved chargers for the appropriate battery pack Do not attempt to use a battery that is leaking swollen or corroded Charger units are not intended for outdoor use Use only indoors 2 10 BATTERY DISPOSAL Before disposing of batteries consult local and governmental regulatory requirements for proper disposal procedure Flex 4EM System Instruction Manual November 2010 7 of 31 2 11 SPECIFIC SYSTEM WARNINGS Below are some specific operating safety tips that should be strictly followed when operating a Flex 4EM system 1 Check the Status LED on the transmitter for any signs of low battery power refer to page 28 2 Check the Status LED on the transmitter for any s
30. o indicate how careful and thoughtful actions may prevent injuries damage to equipment or even save a life 2 3 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED CRANES Only properly trained persons designated by management should be permitted to operate radio controlled equipment Radio controlled cranes hoists lifting devices and other material handling equipment should not be operated by any per son who cannot read or understand signs notices and operating instructions that pertain to the equipment 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 is taking any medication that may cause loss of equipment control or is under the influence of alcohol or drugs Flex 4EM System Instruction Manual November 2010 4 of 31 2 4 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 have knowledge of safety rules for radio controlled equipment have the ability to judge distance of moving objects know how to properly test prior to operation be trained in the safe operation of the radio transmitter as it pertains to the crane hoist lifting device or
31. on 29 C Trouble Shooting Tips 30 8 System Specifications 31 Flex 4EM System Instruction Manual November 2010 1 of 31 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 Each Flex system consists of a transmitter handset and receiver unit Other standard equipped accessories include transmitter waist belt spare transmitter power key clear vinyl pouch AA alkaline batteries compass direction decal sheet and user s manual List of notable features include 62 user programmable channels Advanced synthesized RF controls with 62 built in channels there are no more fixed channel and fragile quartz crystals to break Automatic channel scanning receiver No more hassle of climbing up the crane to change receiver channels Over one million unique ID codes 20bit Each and every Flex system has its own unique ID codes and serial number no repeats Advanced controls The Flex system utilizes advanced microprocessor controls with 32bit CRC and Hamming Code which provide ultra fast safe precise and error free encoding and decoding Unique I CHIP design The I CHIP functions in a way that is very similar to SIM cards used on mobile p
32. ossess the same serial number ID code as the receiver If the Status LED on the decoder module displays a constant red light after inserting the I CHIP programming failed then you must reinsert the I CHIP one more time On the other hand if you wish to transfer system information from the I CHIP to the receiver then you must first insert JP6 jumper prior to inserting the I CHIP then wait for the green light to appear on the Status LED At this time the receiver should also possess the same system information as the I CHIP Please note that the receiver unit must be powered in order to proceed with the programming 6 Fuse Ratings 110 410 24VAC 42 amp 48VAC 12 24VDC 120VAC 460VAC Pee 5 0A clear 5 0A clear 5 0A clear 5 0A clear 5 0A clear 5 0A clear 5 0A clear ere 0 5A blue 0 5A blue 0 5A blue 0 5A blue 1 0A red 1 0A red 2 0A purple Flex 4EM System Instruction Manual November 2010 21 of 31 5 System Channels Table Channel Frequency gei Channel Frequency dg 01 433 000MHZ 000000 32 433 775MHZ 100000 01 433 000MHZ 000001 33 433 800MHZ 100001 02 433 025MHZ 000010 34 433 825MHZ 100010 03 433 050MHZ 000011 35 433 850MHZ 100011 04 433 075MHZ 000100 36 433 875MHZ 100100 05 433 100MHZ 000101 37 433 900MHZ 100101 06 433 125MHZ 000110 38 433 925MHZ 100110 07 433 150MHZ 000111 39 433 950MHZ 1
33. ransmitter on standby Flex 4EM System Instruction Manual November 2010 28 of 31 Receiver STATUS Light Indication Type Display Type Indication 1 Fast green blinks Decoding in process 2 Slow green blinks Decoding on standby 3 Slow red blinks Stop E Biondi receiver 4 Two red blinks Receiver MAIN jammed or defective 5 Fast red blinks Incorrect transmitter serial number ID code 6 Constintred Receiver M i LV output relay 7 No light displayed Decoding microprocessor is defective 3 Receiver SQ Light Indication Type Display Type Red Indication 1 On Transmission received 2 off No transmission 3 Blinks intermittently Other radio interference 4 Receiver POWER Light Indication Type Display Type Red Indication 1 On Power to receiver 2 Off No power to receiver 5 Receiver COM Light Indication Type Display Type Red Indication 1 On Power to relay board 2 Off No power to relay board Flex 4EM System Instruction Manual November 2010 29 of 31 C TROUBLE SHOOTING TIPS Problems Possible Reasons Suggestions Transmitter low battery power Check the transmitter battery level Prior to turning on the transmitter power switch Emergency stop button make sure that the red emergency stop button
34. switches should never be mechanically blocked ON or OFF When not in use the operator should turn the transmitter OFF A secure storage space should be provided for the transmitter unit and the transmitter unit should always be placed there when not in use This precaution will help prevent unauthorized people from operating the material handling equipment Spare transmitters should be stored in a secure storage space and only removed from the storage space after the current transmitter in use has been turned OFF taken out of the service area and secured 2 6 PRE OPERATION TEST At the start of each work shift or when a new operator takes control of the crane operators should do as a minimum the following steps before making lifts with any crane or hoist Test all warning devices Test all direction and speed controls Test the transmitter emergency stop Flex 4EM System Instruction Manual November 2010 6 of 31 2 7 BATTERIES N WARNING KNOW AND FOLLOW PROPER BATTERY HANDLING CHARGING AND DISPOSAL PROCEDURES IMPROPER BATTERY PROCEDURES CAN CAUSE BATTERIES TO EXPLODE OR DO OTHER SERIOUS DAMAGE FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT 2 8 BATTERY HANDLING Use only batteries approved by Magnetek for the specific product Do not dispose of a battery pack in fire it may explode Do not attempt to open the battery pack Do not short circuit the battery For intri
35. y to those who know the code If this feature is desired set up as follows prior to rotating the transmitter power key switch to START position to begin operation you first enter a 4 digit security code in order to proceed further When this 4 digit security code is entered correctly a green light will appear on the Status LED Please refer to the instruction below on how to program the 4 digit security code a Release E Stop then press and hold PB1 PB2 PB3 and PB4 all at once then rotate the power key to START position b A constant orange light will appear on the Status LED telling you that you are in the security code programming mode c Fornewly purchased systems with the security code function deactivated default setting press PB1 four times 1111 to activate the security code function At this time the Status LED on the transmitter will blink orange slowly telling you that the 4 digits entered is correct Then select your own 4 digit security code by pressing PB1 PB2 PB3 or PB4 on the transmitter four presses randomly At this time fast orange blinks are displayed on the Status LED telling you to reconfirm the 4 digit security code you have just entered A green light will appear once you have re entered the same 4 digit security code again programming completed If any mistake is made during this process or if a red light is shown on the Status LED after you have re entered the security code incorrect input or even i
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