Magnetek Flex 12EX System User Manual Download

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Flex 8EX and 12EX EU Systems

Radio Control Equipment

Instruction Manual

Part Number: 191-90100-3201_R00

March

2018

Summary of Contents for Flex 12EX System

Page 2: ...Flex 8EX 12EX EU System Instruction Manual March 2018 Page 2 of 66 Page Intentionally Left Blank...

Page 3: ...Illustration 14 3 1 2 Internal Illustration 16 3 2 Transmitter Handset A B 18 3 2 1 External Illustration 18 3 2 2 Internal Illustration 20 3 3 Receiver Unit 22 3 3 1 External Illustration 22 3 3 2 I...

Page 4: ...4 3rd Speed Pushbutton Operating Procedure 60 7 1 5 Pitch Catch Operating Procedure 60 7 1 6 Automatic Channel Scanning Operating Procedure 60 7 1 7 Changing Transmitter Batteries 61 7 2 Status Light...

Page 5: ...62 783 3510 Service 262 783 3508 Magnetek Inc has additional satellite locations for Canada and the United States For more information please visit http www magnetekmobilehydraulic com 2018 MAGNETEK A...

Page 6: ...to change receiver channels Over 1 million unique ID codes 20 bit Every Flex system has its own unique ID codes and serial number no repeats Advanced controls The Flex system utilizes advanced microp...

Page 7: ...s of the equipment where the radio system is used Plant safety rules and procedures of the employers and the owners of facilities where the Magnetek Products are being used Regulations issued by the O...

Page 8: ...es 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...

Page 9: ...s 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 cra...

Page 10: ...sferring 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 ope...

Page 11: ...uld 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 handli...

Page 12: ...ge 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...

Page 13: ...ED on the transmitter for any signs of low battery power see Section 7 2 on page 62 Check the Status LED on the transmitter for any signs of irregularities see Section 7 2 on page 62 Make sure the sys...

Page 14: ...External Illustration Fig 1 Flex 8EX 1 Emergency Stop Button 9 Pushbutton 5 2 Removable Power Key Switch 10 Pushbutton 7 3 Pushbutton 2 11 Strap Ring 4 Pushbutton 4 12 System Information 5 Pushbutton...

Page 15: ...button 5 2 Removable Power Key Switch 12 Pushbutton 7 3 Pushbutton 2 13 Pushbutton 9 4 Pushbutton 4 14 Pushbutton 11 5 Pushbutton 6 15 Strap Ring 6 Pushbutton 8 16 System Information 7 Pushbutton 10 1...

Page 16: ...arch 2018 Page 16 of 66 3 1 2 Internal Illustration Fig 3 Flex 8EX 1 Encoder Board 6 I CHIP 2 Aerial Antenna 7 Function Dipswitch 3 Transmitting Module 8 Channel Dipswitch 4 Status LED Display 9 Batte...

Page 17: ...tion Manual March 2018 Page 17 of 66 Fig 4 Flex 12EX 1 Encoder Board 6 I CHIP 2 Aerial Antenna 7 Function Dipswitch 3 Transmitting Module 8 Channel Dipswitch 4 Status LED Display 9 Battery Contact Mec...

Page 18: ...ration Fig 5 Flex 8EX 1 Emergency Stop Button 9 Pushbutton 5 2 Removable Power Key Switch 10 Pushbutton 7 3 Pushbutton 2 11 Strap Ring 4 Pushbutton 4 12 System Information 5 Pushbutton 6 13 System Cha...

Page 19: ...2 Removable Power Key Switch 12 Pushbutton 7 3 Pushbutton 2 13 Pushbutton 9 4 Pushbutton 4 14 Pushbutton 11 5 Pushbutton 6 15 Strap Ring 6 Pushbutton 8 16 System Information 7 Pushbutton 10 17 System...

Page 20: ...arch 2018 Page 20 of 66 3 2 2 Internal Illustration Fig 7 Flex 8EX 1 Encoder Board 6 I CHIP 2 Aerial Antenna 7 Function Dipswitch 3 Transmitting Module 8 Channel Dipswitch 4 Status LED Display 9 Batte...

Page 21: ...tion Manual March 2018 Page 21 of 66 Fig 8 Flex 12EX 1 Encoder Board 6 I CHIP 2 Aerial Antenna 7 Function Dipswitch 3 Transmitting Module 8 Channel Dipswitch 4 Status LED Display 9 Battery Contact Mec...

Page 22: ...018 Page 22 of 66 3 3 Receiver Unit 3 3 1 External Illustration Fig 9 1 Shock Mount 6 COM LED Display 2 Optional External Antenna Jack 7 Output Contact Diagram 3 Power LED Display 8 System Information...

Page 23: ...Flex 8EX 12EX EU System Instruction Manual March 2018 Page 23 of 66 3 3 2 Internal Illustration Fig 10 1 AC Line Filter 4 Decoder Module 2 Power Transformer 5 Output Relay Board 3 Receiving Module...

Page 24: ...ming see Fig 12 The system channels table in Section 5 on page 52 illustrates which dipswitch setting corresponds to which channel Once the transmitter channel is altered be sure to change the receive...

Page 25: ...B8 for 8EX PB7 PB12 for 12EX Fig 13 After the pushbutton is released the transmitter will continue to transmit neutral signals to the receiver for up to 1 minute After 1 minute the transmitter will ce...

Page 26: ...al Normal Normal Normal 2 00000101 Normal Normal Normal LED 4 3 00000110 Normal Normal LED 3 LED 4 4 00000111 Normal LED 2 LED 3 LED 4 5 00001000 LED 1 LED 2 LED 3 LED 4 DIP PB7 PB8 PB9 PB10 PB11 PB12...

Page 27: ...Selector type with designated LED Display LED 1 2 or LED 3 4 DIP PB5 PB6 PB7 PB8 6 00101111 Normal Normal A 1 2 Normal 7 00110000 Normal Normal B 1 2 Normal 8 00110001 Normal Normal C 1 2 Normal 9 001...

Page 28: ...Normal A 3 4 Normal Normal Normal Normal 15 00110100 Normal B 3 4 Normal Normal Normal Normal 16 00110101 Normal C 3 4 Normal Normal Normal Normal 17 00110110 Normal D 3 4 Normal Normal Normal Normal...

Page 29: ...l Normal Normal A 3 4 Normal Normal 33 01000110 Normal Normal Normal B 3 4 Normal Normal 34 01000111 Normal Normal Normal C 3 4 Normal Normal 35 01001000 Normal Normal Normal D 3 4 Normal Normal 36 01...

Page 30: ...l Normal Normal Normal Normal A 3 4 51 01011000 Normal Normal Normal Normal Normal B 3 4 52 01011001 Normal Normal Normal Normal Normal C 3 4 53 01011010 Normal Normal Normal Normal Normal D 3 4 54 01...

Page 31: ...s in Section 4 2 5 on page 48 With inline pushbutton configuration PB1 and PB2 still correspond to output relay K1 K4 PB3 and PB4 correspond to relay K5 K8 etc For 8EX Fig 14 NOTE PB8 is not available...

Page 32: ...Normal Normal 66 00010100 Normal Normal LED 3 LED 4 Normal Normal 67 00010101 Normal LED 2 LED 3 LED 4 Normal Normal 68 00010110 LED 1 LED 2 LED 3 LED 4 Normal Normal 69 00001001 Normal Normal Normal...

Page 33: ...ector type with designated LED Display LED 1 2 or LED 3 4 DIP PB5 PB6 PB7 PB8 29 01110011 Normal Normal A 1 2 Normal 30 01110100 Normal Normal B 1 2 Normal 31 01110101 Normal Normal C 1 2 Normal 32 01...

Page 34: ...Normal Normal 80 01110110 D 1 2 Normal Normal Normal 81 00110011 Normal A 3 4 Normal Normal 82 00110100 Normal B 3 4 Normal Normal 83 00110101 Normal C 3 4 Normal Normal 84 00110110 Normal D 3 4 Norm...

Page 35: ...mal 98 10000100 Normal D 1 2 Normal Normal 99 01000101 Normal Normal A 3 4 Normal 100 01000110 Normal Normal B 3 4 Normal 101 01000111 Normal Normal C 3 4 Normal 102 01001000 Normal Normal D 3 4 Norma...

Page 36: ...mal 116 10010010 Normal Normal D 1 2 Normal 117 01010111 Normal Normal Normal A 3 4 118 01011000 Normal Normal Normal B 3 4 119 01011001 Normal Normal Normal C 3 4 120 01011010 Normal Normal Normal D...

Page 37: ...ect 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 Examples Pressing PB2 two times and then PB1 four times will give you c...

Page 38: ...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...

Page 39: ...rding to the channel and pushbutton configurations set on these two dipswitches rather than the ones stored inside the I CHIP Every time the settings on these two dipswitches are changed the new setti...

Page 40: ...receiver module see Fig 17 Only the first six 6 positions are used for channel programming see Fig 18 The system channels table in Section 5 on page 52 illustrates which dipswitch setting corresponds...

Page 41: ...2 4 output relays per motion separate 1st and 2nd speed output relays Output relays with Forward 1st speed F1 Reverse 1st speed R1 Forward 2nd speed F2 and Reverse 2nd speed R2 Forward and Reverse 2nd...

Page 42: ...st output relays engaged at 2nd speed 5 4 output relay configuration with Forward Slow and Fast output relays engaged at 2nd speed NOTE See Section 4 2 4 on page 45 on how to set this function R2 F2 R...

Page 43: ...ng to that pushbutton will open see Section 4 2 4 on page 45 on how to set to this function This type of contact usually applies to external applications such as horns or buzzers 4 2 2 7 Toggled Conta...

Page 44: ...ystem the system preset at channel 62 is ineffective because the 2nd transmitter cannot be set to Ch 63 If your system is preset at Ch 62 be sure to change it to another channel 4 2 3 Receiver Auto Sc...

Page 45: ...nt pushbuttons see Fig 19 Fig 20 and Fig 21 Only the first seven 7 dipswitch positions are used counting from left to right The 8th dipswitch position far right is not used Fig 19 Fig 20 Fig 21 Manufa...

Page 46: ...ommand is initiated the OFF relay is activated 2 0001001 ON START OFF START Prior to pressing the button you must first rotate and hold the power key switch at the START position to activate ON or OFF...

Page 47: ...annel For example if the system is preset at Ch 01 then the 2nd transmitter should be set to Ch 02 Furthermore you must also set the dipswitch on the receiving module positions 7 and 8 to the 10 posit...

Page 48: ...onnect time Start function transmitter pushbutton layout system information serial number ID code programming and system testing Jumpers 1 7 are located on the decoder module above the four 4 for Flex...

Page 49: ...IN deactivated rotate the trans mitter power key switch to the START position to reactivate the receiver MAIN JP4 Blank JP5 Blank Standard right to left pushbutton configuration for all models JP4 Ins...

Page 50: ...solid 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 possess the same serial number ID code as the receiver If th...

Page 51: ...220 240VAC or 24VAC Position 3 380 400VAC or 42VAC Position 4 410 460VAC or 48VAC or 12 24VDC For system with 24 42 48VAC power supply For system with 12 24VDC power supply Fuse Ratings FUSE 110 120VA...

Page 52: ...01 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 1...

Page 53: ...Flex 8EX 12EX EU System Instruction Manual March 2018 Page 53 of 66 6 Receiver Installation 6 1 Output Relay Contact Diagrams 6 1 1 Flex 8EX...

Page 54: ...sed closed and 4 relay opened closed configuration see Section 4 2 2 2 on page 41 For different voltage settings see Section 4 2 7 on page 51 For F9 and F10 power fuse ratings see Section 4 2 7 on pag...

Page 55: ...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 installati...

Page 56: ...e receiver where the antenna is free from any obstacles from all directions to avoid the possibility of antenna damage see Fig 28 Fig 28 4 When installing an external antenna you must connect the SMA...

Page 57: ...operly opens and closes the mainline disconnect contactor 2 Test the operation of each function to ensure it corresponds to the transmitter direction labels or the pendant it is replacing 3 Test the l...

Page 58: ...tate it clockwise to the ON position 3 After turning on the transmitter power check the Status LED on the transmitter handset for any sign of system irregularities see Section 7 2 on page 62 If the sy...

Page 59: ...iver MAIN will be disconnected temporarily To resume operation rotate the power key to the START position depending on JP3 setting see Section 4 2 5 on page 48 Refer to the Continuous Transmitting Tim...

Page 60: ...ontrol of the crane unless the 1st operator presses the Pitch pushbutton 2 seconds If the operator unintentionally presses the Pitch pushbutton during operation rotate the power key to the Catch posit...

Page 61: ...es by unscrewing the battery cover located on the backside of the transmitter see Fig 30 During battery installation make sure that the blue ribbon is centered between the two batteries After changing...

Page 62: ...2 red blinks type 3 above find out which pushbutton is defective by pressing all the pushbuttons on the transmitter one at a time If the pushbutton is in good working order the LED will not light up w...

Page 63: ...receiver MAIN deactivated 4 2 red blinks Receiver MAIN jammed or defective 5 Fast red blinks Incorrect transmitter serial number ID code 6 Solid red Receiver under voltage LV output relay activated 7...

Page 64: ...th have the same serial number ID code System out of range Make sure the startup procedure is ini tiated within 100 meters 300 feet from the receiver location No response when transmitter push button...

Page 65: ...Bm Antenna Impedance 50 ohms Responding Time 60 milliseconds average Transmitting Power 1 0 mW Enclosure Type NEMA 4X Enclosure Rating IP66 Output Contact Rating 250V 8 Amps Transmitter Operating Volt...

Page 66: ...o Equipment Direc ve RE D 1999 5 EC The standards relevant for the evalua on of the product referenced above conformity to the direc ve requirements are as follows EN 301 489 1 EN 301 489 3 EN 300 220...

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