FlexEX - Sundrive
Contents
1. 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 a b c above and press PB1 four times as your new security code security code function disabled e f you do not remember the 4 digit security code then you must contact your dealer or distributor for further assistance Flex 6EX System Instruction Manual June 2010 17 of 37 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 I CHIP works exactly the same way as it stores information such as system serial 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 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 I CHIP If both 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 in2. Flex 6EX System Radio Control Equipment Instruction Manual MAGNETEK MATERIAL HANDLING ENRANGE 0 FLEX 6EX ME June 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 Flex 6EX System Instruction Manual June 2010 1 of 37 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
3. 2 Power LED Display 5 COM LED Display 3 Status LED Display 6 Output Contact Diagram 7 Cord Grip Flex 6EX System Instruction Manual June 2010 13 of 37 2 Internal Illustration H ek lek uuu Fig 06 Receiving Module Decoder Relay Board 3 AC Line Filter Relay Board 4 Power Transformer Flex 6EX System Instruction Manual June 2010 14 of 37 4 Function Settings A TRANSMITTER HANDSET 1 System Channel Settings CHANNEL BnpHpRRn uboubub 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 27 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 transm
4. Programming Port PORT 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 a system serial number ID code from the I CHIP to the receiver or vice versa If you wish to transfer system information from the receiver to the 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 displays a constant green light within 2 seconds and then take the I CHIP out of the programming port programming completed At this time the I CHIP should also possess 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 I CHIP to 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 Fuse Ratings 110 220 380 410 24VAC 42 amp 48VAC 12 24VDC 120VAC 240VAC 400VAC 460VAC 5 0A clear 5 0A clear 5 0A clear 5 0A clear 5 0A clear 5 0A c
5. 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 Flex 6EX System Instruction Manual June 2010 31 of 37 f In case of an emergency pressing 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 the Start position to resume operation depends on JP3 setting on page 25 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 25 To resume operation just rotate the power key switch to START position to reconnect the receiver MAIN h Turn off the transmitter 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 2 Automatic Channel Scanning Operating Procedure After changing transmitter channel refer to page 15 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
6. for the installation use operation and service of Magnetek 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 th
7. interlocked settings allow the two adjacent push buttons be used simultaneously Non interlocked settings are usually applied to a crane s auxiliary functions such as lights horn 3 speed and auxiliary stop Each dip switch on the decoder module corresponds to one 1 motion or two 2 adjacent push buttons left amp right push buttons Dip Dip Position Setting Function Position 2 4 left button Eunetlon Description Code Setting amp p 1 5 7 right button A 1 000 Normal momentary contact B 1 001 Toggled latching contact Toggled latching contact affected by the C 4 011 E Stop command When E Stop command is initiated all toggled latching relays are also deactivated Example 1 Left button set to function code A right button set to function code A 1000 000 Example 2 Left button set to function code B right button set to function code B 1001 001 Example 3 Left button set to function code A right button set to function code C 1000 011 Example 4 Left button set to function code C right button set to function code B 1011 001 Flex 6EX System Instruction Manual June 2010 24 of 37 5 Jumper Settings Jumper settings are applied to functions such as main disconnect time Start function system information serial number ID code programming and system testing Jumpers 1 7 are located on the decoder relay board bet
8. 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 6EX System Instruction Manual June 2010 30 of 37 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 Turn on 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 Li 15 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 Indicators amp Warnings on page 34 If the system is normal the Status LED will light up green for two 2 seconds d Ifthere 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 25 Thereafter the same Start position will become an auxiliary function with momentary contact refer to page 21 e Now press any push button on the transmitter handset to operate the crane or
9. 0bit Each and every Flex system has its own unique ID codes and serial number never 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 phones 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 150 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 Machinery and Industry Canada Specifications IC Flex 6EX System Instruction Manual June 2010 5 of 37 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
10. 11 SPECIFIC SYSTEM WARNINGS Below are some specific operating safety tips that should be strictly followed when operating a Flex 6EX System 1 Check the Status LED on the transmitter for any signs of low battery power refer to page 34 2 Check the Status LED on the transmitter for any signs of irregularities refer to page 34 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 Flex 6EX System Instruction Manual June 2010 10 of 37 3 General System Information A TRANSMITTER HANDSET 1 External Illustration LL it Q IE fN _ PA Z Fig 01 Fig 02 1 Emergency Stop Button 8 Push Button 5 2 Removable Power Key Switch 9 Strap Ring 3 Push Button 2 10 System Information 4 Push Button 4 11 System Channel 5 Push Button 6 12 Crane Number 6 Push Button 1 13 Battery Cover T Push Button 3 14 FCC Information Flex 6EX System Instruction Manual June 2010 11 of 37 2 Internal Illustration Fig 03 Fig 04 I CHIP Function Dip Switch Channel Dip Switch Battery Contact Mechanism Encoder Board Aerial Antenna Transmitting Module Status LED Display Function LED Displays mio Oe UO Flex 6EX System Instruction Manual June 2010 12 of 37 B RECEIVER UNIT 1 External Illustration Fig 05 1 External Antenna Jack optional 4 SQ LED Display
11. 8 434 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 I CHIP 111111 When set to all 1 the priority goes to the channel assigned inside the I CHIP Flex 6EX System Instruction Manual June 2010 27 of 37 6 Receiver Installation A OUTPUT RELAY CONTACT DIAGRAM Push button 1 2 F1 5A MAIN Function COM 7 K26 FUNC K27 NC MAIN coms 7 MAIN Push button 3 4 Push button 5 6 F3 5A Power Transformer For 3 relay shared 2 speed and 4 relay separate 2 speed configurations please refer to page 20 For 4 relay closed closed and 4 relay opened closed relay configurations please refer to page 21 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 6 is for Normal Close and wire 8 is for Normal Open MAIN output Flex 6EX System Instruction Manual June 2010 28 of 37 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 c
12. 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 AUDIBLE 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 PROCEUDRES 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 I E 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 li
13. ETY 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 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 2 7 BATTERIES A 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 RES
14. June 2010 22 of 37 4 Dip Switch Settings a Interlocked Functions Interlocked means the two adjacent push buttons can not be activated simultaneously as they will cancel each other out Interlocked settings are usually applied to forward and reverse motions Each dip switch on the decoder module corresponds to one 1 motion or two 2 adjacent push buttons refer to Fig 12 amp 13 below Only the first seven 7 dip switch positions are used counting from left to right the 8 dip switch position far right is not used SNOULONPH AV 13H Fig 12 Fig 13 Manufacture preset Dip Settings Function Descriptions of Relays Used 0000000 Normal single speed only F2 amp R2 relays not used 2 0000001 Closed Closed Relay Action at 2 Speed separate 2 speed relay 4 0000010 Closed Closed Relay Action at and Speed shared on speed relay 3 0000011 Opened Closed Relay Action at 2 Speed separate 209 speed relay 4 On Start Off Start Prior to pressing the button you must first rotate 0001001 and hold the power key switch at START position to 2 activate On or Off relays 0001010 FWD REV toggled latched 2 0001011 FWD REV toggled latched and affected by the E stop command 2 Flex 6EX System Instruction Manual June 2010 23 of 37 b Non Interlocked Functions Contrary to interlocked settings non
15. Only the first six 6 positions are used for channel programming refer to Fig 11 below The system channels table located on page 27 illustrates which dip switch setting corresponds to which channel Once the receiver channel is altered make sure to change transmitter channel as well The channel on both transmitter and receiver must be identical in order for system to work To change the transmitter channel please refer to page 15 RRBBBRRR Top slot gt 1 Bottom slot 0 Fig 11 123456 HHHHHHHH B The above dip switch setting 1 0 0 1 0 0 corresponds to channel 36 in the system channels table on page 27 Flex 6EX System Instruction Manual June 2010 19 of 37 2 Output Relay Configurations a Output Relay Types 1 Three 3 output relays per motion shared 2 speed output relay Output relays with Forward 1 speed F1 Reverse 1 speed R1 and Forward Reverse 2 speed F R2 Forward and Reverse 2 speed F R2 shared the same output relay F R2 Four 4 output relays per motion separate 1 and 2 speed output relays Output relays with Forward 1 speed F1 Reverse 1 speed R1 Forward 2 speed F2 and Reverse 2 speed R2 Forward and Reverse 2 speed with separate output relays Fl RI F2 R2 b Output Relay Actions at 2 Speed 1 3 output relays configur
16. Stop command initiated with receiver MAIN deactivated 4 Two red blinks Receiver MAIN jammed or defective 5 Fast red blinks Incorrect transmitter serial number ID code 6 Constant red Receiver under voltage LV output relay activated 7 No light displayed Decoding microprocessor is defective 9 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 6EX System Instruction Manual June 2010 35 of 37 C TROUBLE SHOOTING TIPS Problems Possible Reasons Suggestions No response when transmitter push button is pressed Improper startup amp settings Transmitter has low battery power Check the transmitter battery level Emergency stop button activated prior to startup Prior to turning on the transmitter power switch make sure that the red emergency stop button is elevated Improper startup procedure Redo the startup procedure by holding the power key at START position for up to 2 0 seconds and then release Incorrect system RF channel Check to ensure that the transmitter handset and receiver unit both have the s
17. ULT 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 intrinsically 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 Flex 6EX System Instruction Manual June 2010 9 of 37 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 2
18. ame channel Incorrect system serial number ID code Check to ensure that the transmitter handset and receiver unit both have the same serial number ID code System out of range Make sure that the startup procedure is initiated within 100 meters 300 feet from the receiver location No response when transmitter push button is pressed Damaged hardware Defective transmitting and receiving module Check the SQ display on the face of the receiver unit If it does not light up when push button is pressed then either the transmitting or receiving module is defective First replace the transmitting module If SQ display is still not lit when the push button is pressed go ahead and replace the receiving module Defective encoder board or decoder module If still no response then replace the transmitter encoder board If it still doesn t work then the decoder module is defective No AC power to the receiver Incorrect input voltage Make sure the source voltage is set correctly Blown fuse Check for any blown fuses Incorrect wiring Check input voltage connection Outputs do not correspond to transmitter Incorrect output connection Check the system wiring again Please refer to the output contact diagram inside this manual or on the receiver cover Flex 6EX System Instruction Manual June 2010 36 of 37 8 System Specifications Fre
19. at all operators are properly trained No one should use 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 Flex 6EX System Instruction Manual June 2010 2 of 37 Table of Contents Introduction Radio Controlled Safety General System Information A Transmitter Handset 1 External Illustration 2 Internal Illustration B Receiver Unit 1 External Illustration 2 Internal Illustration Function Settings A Transmitter Handset 1 System Channel Settings 2 Channel Change via Push Buttons 3 Optional 4 Digit Security Code 4 CHIP Receiver Unit 1 System Channel Settings 2 Output Relay Configurations Output Relay Types Output Relay Action at 2 Speed START AUX Function Momentary Contact Toggled Contact Auxiliary STOP Push Button Function 3 Receiver Auto Scanning Settings 4 Dip Switch Settings a Interlocked Functions b Non Interlocked Functions 5 Jumper Settings 6 I CHIP Programming Port 7 Fuse Ratings e oo o System Channels Table Receiver Installation Output Relay Contact Diagram Pre Installation Precautions Step by Step Installation System Testing com Page 11 12 13 14 28 29 30 30 Flex 6EX System Instruction Manual June 2010 3 of 37 7 Operating P
20. ation with Closed Closed contact at 2 speed At 2 speed both 1 speed F1 or R1 and 2 speed F R2 output relays are closed refer to page 23 on how to set to this function Forward 1 speed push button pressed Forward 2 speed push button pressed 1 R1 F R2 F1 R1 F R2 Flex 6EX System Instruction Manual June 2010 20 of 37 F1 F1 2 4 output relays configuration with Opened Closed contact at 2 speed At 2 speed only the 2 speed F2 or R2 output relay is closed refer to page 23 on how to set to this function Forward 1 speed push button pressed Forward 2 speed push button pressed RI F2 R2 Fl RI F2 R2 3 4 output relays configuration with Closed Closed contact at 2 speed At 2 speed both 1 speed F1 or R1 and 2 speed F2 or R2 output relays are closed refer to page 23 on how to set to this function Forward 1 speed push button pressed Forward 2 speed push button pressed RI F2 R2 Fl RI F2 R2 START AUX Function After initiating the START function the Start position will become an auxiliary function with momentary contact For auxiliary applications such as horns or buzzers please connect it to the FUNC output relay wire 5 located inside the receiver unit Momentary Contact When the push button is released the output relay that corresponds to that push button will open refer to page 24 on how to set to this function This type of c
21. ed system 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 if 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 step 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
22. ely 3 2 red blinks followed by a 2 The push button 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 4 No light displayed buttons on the transmitter one at a time If the 9 push button is 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 5 3 red blinks followed by a 2 EEPROM error second pause 6 4 red blinks followed by a 2 Transmitting error system can not 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 Push button pressed signal transmitted r Stop command initiated with receiver 9 SON TER inks MAIN deactivated 10 1 orange blink every 4 seconds Transmitter on standby Flex 6EX System Instruction Manual June 2010 34 of 37 2 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
23. fting 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 to 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 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 e have know
24. itter and the receiver must be identical in order for the system to work To change the receiver channel please refer to page 19 Example I Top slot 1 Bottom slot 0 Fig 08 L3 Se HHBEHBEG The above dip switch setting 1 0 0 1 0 0 corresponds to channel 36 in the system channels table on page 27 Flex 6EX System Instruction Manual June 2010 15 of 37 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 instructions 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 appear on the Status LED showing the current channel setting A 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 o_o IP2 PBlj lt 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 u 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 Sta
25. lear 5 0A clear 0 5A blue 0 5A blue 0 5A blue 0 5A blue 1 0A red 1 0A red 1 0A red Flex 6EX System Instruction Manual June 2010 26 of 37 5 System Channels Table Channel Frequency poen Channel Frequency Qd 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 100111 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 5
26. ledge of hazards pertaining to equipment operation e have knowledge of safety rules for radio controlled equipment e have the ability to judge distance of moving objects Flex 6EX System Instruction Manual June 2010 7 of 37 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 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 ind
27. 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 of functional effectiveness Cautions are high lighted 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 fed eral 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 6EX System Instruction Manual June 2010 6 of 37 2 1 CRITICAL INSTALLATION CONSIDERATIONS Za 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
28. ontact is usually applied to external application such as horns or buzzers Toggled Contact When the push button is released the output relay that corresponds to that push button will remain closed maintained contact until next time the user presses the same push button again refer to page 24 on how to set to this function This type of contact is usually applied to external application such as lights Flex 6EX System Instruction Manual June 2010 21 of 37 f Auxiliary STOP Push Button Function The auxiliary STOP function acts as 2 emergency stop button Other than by emergency stop button and transmitter power key switch the receiver MAIN is also deactivated when this auxiliary stop push button is pressed refer to page 24 on how to set to this function 3 Receiver Auto Scanning Settings Receiver Channel Dip switch RRHRRRRR 1 gt Scans all 62 channels manufacture preset zi For standard operation HBHBBHBB3 2 HERRRRHE Single fixed channel Auto scanning function disabled 78 HBHBHBB3 3 MAR Scanning 2 channels only s 78 HHEHBHBH 4 PERHE Scanning 3 channels only 78 HEEEEEEE fthe 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 6EX System Instruction Manual
29. quency Range Frequency Deviation Number of Channels Modulation Encoder amp Decoder Transmitting Range Frequency Control Receiver Type Receiver Sensitivity 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 gt 100 Meters 300 Feet Synthesized PLL Phase Lock Loop Frequency Auto Scanning 116dBm 50 ohms 60 Milliseconds average 0 3mW NEMA 4 IP 66 250V 8 Amps DC 3 0V 11 0 VA Voltage Setting Min Max 24VAC 22 26VAC 42VAC 38 46VAC 48VAC 43 53VAC 110VAC 104 126VAC 220VAC 207 253VAC 380VAC 351 429VAC 410VAC 400 480VAC 12 24VDC 9 36VDC 25 C 75 C 13 F 167 F 184mm L x 69mm W x 34mm H 165mm L x 125mm W x 75mm H 242g 8 50z 1 8kg 4 0 Ib include output cable Flex 6EX System Instruction Manual June 2010 37 of 37
30. rane 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 p MTN Fig 16 Flex 6EX System Instruction Manual June 2010 29 of 37 For best reception the location of the receiver should be visible to the operator at all time 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 Ensure the selected location has adequate space to accommodate the receiver refer to Fig 16 on page 29 For better reception make sure the receiver is in an upright position Drill one hole 8mm in diameter on the control panel or location where the receiver is to be installed refer to below Make sure the bolt is tightened after installation For system wiring please refer to page 28 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
31. rocedure A Transmitter Operation 1 General Operating Procedure 31 32 2 Automatic Channel Scanning Operating Procedure 32 3 Changing Transmitter Batteries 33 B Status Light Indicators amp Warnings 1 Transmitter STATUS Light Indication 34 2 Receiver STATUS Light Indication 35 3 Receiver SQ Light Indication 35 4 Receiver POWER Light Indication 35 5 Receiver COM Light Indication 35 C Trouble Shooting Tips 36 8 System Specifications 37 Flex 6EX System Instruction Manual June 2010 4 of 37 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 channels 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 2
32. side the I CHIP Every time when the settings on these two dip switches have 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 replaced by the new settings For safety purposes the system serial number ID code stored inside the I CHIP can not 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 transmitter serial number ID code via I CHIP programming port located on the decoder module inside the receiver unit please refer to page 26 on how to program the I CHIP serial number ID code via the 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 09 Flex 6EX System Instruction Manual June 2010 18 of 37 B RECEIVER UNIT 1 System Channel Settings 123 45 678 Fig 10 Even though the Flex system is equipped with an automatic channel scanning mode the user can also set the receiver channel manually Please refer to page 32 on how 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
33. 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 22 if you do not want the receiver to auto scan all 62 channels Change Transmitter Channel Flex 6EX System Instruction Manual June 2010 32 of 37 3 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 S v Fig 17 Flex 6EX System Instruction Manual June 2010 33 of 37 B STATUS LIGHT INDICATORS 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 immediat
34. tus LED via 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 19 and page 32 on how to change the 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 the 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 6EX System Instruction Manual June 2010 16 of 37 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 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 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 For newly purchas
35. ustry 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 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 change any settings or controls without authorization and proper training remove or obscure any warning or safety labels or tags leave any load unattended while lifted leave power on the radio controlled equipment when the equipment is not in operation operate any material handling equipment using a damaged controller because the unit may be unsafe operate manual motions with other than manual power operate radio controlled equipment when low battery indicator is on Flex 6EX System Instruction Manual June 2010 8 of 37 WARNING THE OPERATOR SHOULD NOT ATTEMPT TO REPAIR ANY RADIO CONTROLLER IF ANY PRODUCT PERFORMANCE OR SAF
36. ween the receiving RF module and the output relays refer to Fig 14 below Manufacture preset SYSTEM FUNCTIONS TEST Fig 14 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 en Inserted Blank Receiver MAIN opens after 5 minutes of system inactivity JP1 JP2 i 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 at as t tart ft t t and aft tem inactivit Blank 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 JP6 Program system serial number ID code and channel from decoder module Blank to I CHIP JP6 Program system serial number ID code and channel from I CHIP Inserted to decoder module di For system test only receiver MAIN disabled Inserted y Flex 6EX System Instruction Manual June 2010 25 of 37 6 7 I CHIP
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