Magnetek Flex 8EX A/B User Manual Download

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Flex 8EX-A/B System

Radio Control Equipment

Instruction Manual

0-FLEX-8EXABME-R1

June 2010

Summary of Contents for Flex 8EX A/B

Page 2: ...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 C...

Page 3: ...ration Transmitter Toggle 16 b Standard Push Button Configuration A B Selector 17 c Inline Push Button Configuration Transmitter Toggle 18 d Inline Push Button Configuration A B Selector 19 2 Channel Change via Push Buttons 20 3 Program 4 Digit Security Code 21 4 I CHIP 22 B Receiver Unit 1 System Channel Settings 23 2 Output Relay Configurations a Output Relay Types 24 b Output Relay Action at 2n...

Page 4: ... 7 Operating Procedure A Transmitter Operation 1 General Operating Procedure 36 37 2 Rotary Select A B Operating Procedure 37 3 Push Button Select A B Operating Procedure 37 4 3rd Speed Push Button Operating Procedure 37 5 Pitch Catch Operating Procedure 38 6 Automatic Channel Scanning Operating Procedure 38 7 Changing Transmitter Batteries 38 B Status Light Indicators Warnings 1 Transmitter Statu...

Page 5: ...e 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 Occupational Health and Safety Administration OSHA Applicable local state or federal codes ordinances standards and requirements or Safety standards and practices for the industries in which Magnetek Products...

Page 6: ...iver channels Over one million unique ID codes 20bit 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 SI...

Page 7: ...ting 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 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 o...

Page 8: ... 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 1 2 GENERAL Radio controlled material handli...

Page 9: ...nd 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 proc...

Page 10: ... MAGNETEK FOR EVALUATION AND REPAIR FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT 1 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 the...

Page 11: ... and storage i e not in direct sunlight or close to a heating source 1 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 ...

Page 12: ...y power refer to page 39 2 Check the Status LED on the transmitter for any signs of irregularities refer to page 39 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 a crane or equipment with two transmitter handsets at the same time unless they are programmed with Pitch Catch function For information on ...

Page 13: ... Push Button Configuration Fig 01 Fig 02 1 Emergency Stop Button 9 Push Button 5 2 Removable Power Key Switch 10 Push Button 7 3 Push Button 2 11 Strap Ring 4 Push Button 4 12 System Information 5 Push Button 6 13 System Channel 6 Select A B A B Rotary Switch 14 Crane Number 7 Push Button 1 15 Battery Cover 8 Push Button 3 16 FCC Information ...

Page 14: ...al June 2010 12 of 42 2 Internal Illustration Fig 03 Fig 04 1 Encoder Board 6 I CHIP 2 Arial Antenna 7 Function Dip Switch 3 Transmitting Module 8 Channel Dip Switch 4 Status LED Display 9 Battery Contact Mechanism 5 Function LED Displays ...

Page 15: ...l June 2010 13 of 42 B RECEIVER UNIT 1 External Illustration Fig 05 1 Shock Mount 6 COM LED Display 2 External Antenna Jack 7 Output Contact Diagram 3 Power LED Display 8 System Information 4 Status LED Display 9 Cord Grip 5 SQ LED Display ...

Page 16: ...Flex 8EX A B System Instruction Manual June 2010 14 of 42 2 Internal Illustration Fig 06 1 AC Line Filter 4 Decoder Module 2 Power Transformer 5 Output Relay Board 3 Receiving Module ...

Page 17: ... used for channel programming refer to Fig 08 below The system channels table located on page32 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 pag...

Page 18: ...backside of the transmitter encoder board refer to Fig 09 below The LED 1 through LED 4 shown inside the shaded box see below illustrates which LED on the transmitter will light up when the designated push button PB5 PB7 is pressed Fig 09 DIP PB5 PB6 PB7 1 00000000 Normal Normal Normal 2 00000101 Normal Normal Normal 3 00000110 Normal Normal LED 3 4 00000111 Normal LED 2 LED 3 5 00001000 LED 1 LED...

Page 19: ...10000 Normal Normal B 1 2 8 00110001 Normal Normal C 1 2 9 00110010 Normal Normal D 1 2 10 00110011 Normal Normal Normal 11 00110100 Normal Normal Normal 12 00110101 Normal Normal Normal 13 00110110 Normal Normal Normal 14 00110111 Normal Normal A 1 2 15 00111000 Normal Normal A 1 2 16 00111001 Normal Normal A 1 2 17 00111010 Normal Normal A 1 2 18 00111011 Normal Normal B 1 2 19 00111100 Normal N...

Page 20: ...n configuration please refer to JP4 and JP5 jumpers setting on page 30 With inline push button configurations PB1 PB2 still corresponds to output relay K1 K4 PB3 PB4 corresponds to relay K5 K8 etc Fig 10 DIP PB5 PB6 PB7 24 00000000 Normal Normal Normal 25 00000101 Normal Normal Normal 26 00010100 Normal Normal LED 3 27 00010101 Normal LED 2 LED 3 28 00010110 LED 1 LED 2 LED 3 PB5 PB7 Push button n...

Page 21: ...0100 Normal Normal B 1 2 31 01110101 Normal Normal C 1 2 32 01110110 Normal Normal D 1 2 33 00110011 Normal Normal Normal 34 00110100 Normal Normal Normal 35 00110101 Normal Normal Normal 36 00110110 Normal Normal Normal 37 01110111 Normal Normal A 1 2 38 01111000 Normal Normal A 1 2 39 01111001 Normal Normal A 1 2 40 01111010 Normal Normal A 1 2 41 01111011 Normal Normal B 1 2 42 01111100 Normal ...

Page 22: ... b 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 Examples Pressing PB2 two times and then PB1 four times will give you channel 24 Pressing PB1 nine times with give you channel 09 c When finished the newly selected channel will appear on the Status LED via a series of green and red blinks again d Exit the channel ...

Page 23: ...his 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...

Page 24: ...ill 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...

Page 25: ...d on the receiver module refer to Fig 12 above only the first six 6 positions are used for channel programming refer to Fig 13 below The system channels table located on page 32 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 the receiver must be identi...

Page 26: ...output relay 2 Four 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 speed with separate output relays b Output Relay Actions at 2nd Speed 1 3 output relays configuration with Closed Closed contact at 2nd speed At 2nd speed both 1st speed F1 or R1 an...

Page 27: ...t relays configuration with Closed Closed contact at 2nd speed At 2nd speed both 1st speed F1 or R1 and 2nd speed F2 or R2 output relays are closed refer to page 28 on how to set to this function Forward 1 st speed push button pressed Forward 2 nd speed push button pressed c ON OFF Push Button Function The user can set any of the two adjacent push buttons on the transmitter to behave like a mechan...

Page 28: ...2nd speed output relays will open for up to 1 0 second and then with 1st speed output relay closed thereafter refer to page 28 on how to set to this function g Momentary Contact When the push button is released the output relay that corresponds to that push button will open refer to page 29 on how to set to this function This type of contact is usually applied to external applications such as horn...

Page 29: ...8 on the receiving module should be set to 01 as this will allow the receiver to scan only Ch 01 and Ch 02 please refer to the illustration below On the other hand since there are only 62 available channels on the Flex system the system preset at channel 62 is ineffective because the 2nd transmitter can not be set to Ch 63 If your system is preset at Ch 62 make sure to change it to another channel...

Page 30: ...ons of Relays Used 0000000 Normal single speed only F2 R2 relays not used 2 0000001 Closed Closed Relay Action at 2nd Speed separate 2nd speed relay 4 0000010 Closed Closed Relay Action at 2nd Speed shared 2nd speed relay 3 0000011 Opened Closed Relay Action at 2nd Speed separate 2nd speed relay 4 0000110 On right button Off left button 2 0001000 On Off affected by the E stop command When E stop c...

Page 31: ...s initiated receiver MAIN will not be deactivated F 1 110 Pitch Catch Type 2 When Pitch release function is initiated receiver MAIN will be deactivated G 1 111 Auxiliary Stop H 1 100 Normal Start function For added safety you must first rotate and hold the power key switch at START position and then press the intended push button at the same time to activate the output relay Example 1 Left button ...

Page 32: ...nserted Receiver MAIN opens after 60 minutes of system inactivity JP3 Blank Press any push button on the transmitter to activate the receiver MAIN at system startup after E stop reset and after system inactivity refer to JP1 JP2 settings above JP3 Inserted Rotate the power key switch to START position to activate the receiver MAIN at system startup after E stop reset and after system inactivity re...

Page 33: ...ogramming 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 receive...

Page 34: ...Flex 8EX A B System Instruction Manual June 2010 32 of 42 ...

Page 35: ...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 4...

Page 36: ...ration please refer to pages 24 25 For the 4 relay closed closed and 4 relay opened closed relay configuration please refer to pages 24 25 For different voltage settings please refer to page 31 For F9 and F10 power fuse ratings please refer to page 31 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 ...

Page 37: ...rior 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 Fig 19 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 ne...

Page 38: ...6 Drill two holes 10mm in diameter on the control panel or location where the receiver is to be installed refer to Fig 19 on page 34 7 Make sure the two bolts are tightened after installation 8 For system wiring please refer to page 33 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 op...

Page 39: ...of the transmitter handset and rotate it clockwise to the 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 Indicators Warnings on page 39 If the system is normal the Status LED will light up green for two 2 seconds d If there are no signs of any system irregularities then rotate the powe...

Page 40: ...key switch to START position to reconnect the receiver MAIN h Turn off the transmitter power by rotating the power key counter clockwise to the Off position it will disconnect the transmitter power and the receiver MAIN altogether Turn it further counter clockwise to release the key 2 Rotary Select A B Operating Procedure This changeover function is designed specifically for crane systems with dua...

Page 41: ... switch to the 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 you must first deactivate the receiver MAIN by shutting off the transmitter power or press down the emergency stop b...

Page 42: ... 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 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 5 3 red blinks followed by a 2 second pause EEPROM err...

Page 43: ... transmitter serial number ID code 6 Constant red Receiver under voltage LV output relay activated 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 ...

Page 44: ...at 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 the push button is pressed then either the transmitting or receiving module is defective First replace the trans...

Page 45: ...ning Receiver Sensitivity 116dBm Antenna Impedance 50 ohms Responding Time 60 Milliseconds average Transmitting Power 0 3mW Enclosure Type NEMA 4X Enclosure Rating IP 66 Output Contact Rating 250V 10 Amps Transmitter Operating Voltage DC 3 0V Receiver Power Consumption 11 0 VA Receiver Supply Voltage Voltage Setting Min Max 24VAC 22 26VAC 42VAC 38 46VAC 48VAC 43 53VAC 110VAC 104 126VAC 220VAC 207 ...

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