Flex Mini System Radio Control Equipment Instruction Manual

Flex Mini System
Radio Control Equipment
Instruction Manual
191-75020-0001 R4
June 2015
© Copyright 2015 Magnetek Material Handling
SERVICE INFORMATION
Your New Radio System
Thank you for your purchase of Magnetek’s Enrange™ Flex Mini radio remote control system.
Without a doubt, our Flex Mini 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
World Headquarters:
Magnetek, Inc.
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
Telephone:
Website:
e-mail:
+1.800.288.8178
www.magnetek.com
[email protected]
Fax Numbers:
Main:
+1.800.298.3503
Sales:
+1.262.783.3510
Service:
+1.262.783.3508
Magnetek, Inc. has additional satellite locations for Canada and the United States. For more
information, please visit http://www.magnetek.com.
Flex Mini System Instruction Manual
June 2015
Page 2 of 25
PREFACE AND SAFETY
©2015 MAGNETEK
All rights reserved. This notice applies to all copyrighted materials included with this product,
including, but not limited to, this manual. This manual is intended for the sole use of the persons to
whom it was provided, and any unauthorized distribution of the manual or dispersal of its contents is
strictly forbidden. This manual may not be reproduced in whole or in part by any means whatsoever
without the expressed written permission of Magnetek.
Product 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 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:
Instructions, manuals, and safety warnings of the manufacturers 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 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 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
Magnetek Products prior to becoming familiar with and being trained in these requirements and
the instructions and safety recommendations in this manual.
Product Warranty Information
Magnetek, hereafter referred to as Company, assumes no responsibility for improper programming of
a device (such as a drive or radio) by untrained personnel. A device should only be programmed by a
trained technician who has read and understands the contents of the relevant manual(s). Improper
programming of a device can lead to unexpected, undesirable, or unsafe operation or performance of
the device. This may result in damage to equipment or personal injury. Company shall not be liable
for economic loss, property damage, or other consequential damages or physical injury sustained by
the purchaser or by any third party as a result of such programming. Company neither assumes nor
authorizes any other person to assume for Company any other liability in connection with the sale or
use of this product.
For information on Magnetek’s product warranties by product type, please visit www.magnetek.com.
Flex Mini System Instruction Manual
June 2015
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TABLE OF CONTENTS
SERVICE INFORMATION .................................................................................................................... 2
PREFACE AND SAFETY ..................................................................................................................... 3
Product Safety Information ............................................................................................................... 3
Product Warranty Information .......................................................................................................... 3
TABLE OF CONTENTS ....................................................................................................................... 4
RADIO CONTROLLED SAFETY ......................................................................................................... 5
CRITICAL INSTALLATION CONSIDERATIONS .............................................................................. 6
1. GENERAL SYSTEM INFORMATION ............................................................................................ 10
1.1 TRANSMITTER........................................................................................................................ 10
1.1.1 External Illustration ........................................................................................................... 10
1.1.2 Internal Illustration............................................................................................................. 11
1.2 RECEIVER............................................................................................................................... 12
1.2.1 External Illustration ........................................................................................................... 12
1.2.2 Internal Illustration............................................................................................................. 13
2. FUNCTION SETTINGS .................................................................................................................. 14
2.1 TRANSMITTER........................................................................................................................ 14
2.1.1 Channel Settings............................................................................................................... 14
2.1.2 Keypad Type Settings ....................................................................................................... 15
2.1.3 Remote Pairing ................................................................................................................. 16
2.2 RECEIVER............................................................................................................................... 18
2.2.1 Dipswitch Settings ............................................................................................................. 18
2.2.2 Jumper Settings (for units with the external Pairing button) .............................................. 19
2.2.3 External Programming (for units with the external Pairing button) ..................................... 19
2.2.4 Fuse Ratings ..................................................................................................................... 19
2.2.5 Using External Antenna (optional) ..................................................................................... 20
3. RECEVIER INSTALLATION .......................................................................................................... 21
4. OPERATING PROCEDURE........................................................................................................... 23
4.1 GENERAL OPERATING PROCEDURE ................................................................................... 23
4.2 CHANGING TRANSMITTER BATTERIES ............................................................................... 23
5. STATUS & WARNINGS ................................................................................................................. 24
5.1 TRANSMITTER STATUS LIGHT INDICATIONS ...................................................................... 24
5.2 RECEIVER STATUS LIGHT INDICATIONS ............................................................................. 24
5.3 RECEIVER COM LIGHT INDICATIONS .................................................................................. 24
5.4 RECEIVER POWER LIGHT INDICATIONS ............................................................................. 24
6. SYSTEM SPECIFICATIONS .......................................................................................................... 25
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June 2015
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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 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 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.
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June 2015
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CRITICAL INSTALLATION CONSIDERATIONS
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 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 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, 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.
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 to indicate how careful and thoughtful actions may prevent
injuries, damage to equipment, or even save a life.
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 person 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.
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June 2015
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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 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 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
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June 2015
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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
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.
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.
PRE-OPERATION TEST
At the start of each work shift, or when a new operator takes control of the equipment, operators should do, as a
minimum, the following steps before operation:
Test all warning devices.
Test all direction and speed controls.
Test the transmitter stop function.
Flex Mini System Instruction Manual
June 2015
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BATTERIES
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.
BATTERY HANDLING
Do not dispose of batteries in fire; it may explode.
Do not short circuit the batteries.
For intrinsically safe environments only use specified Magnetek intrinsically safe batteries.
BATTERY DISPOSAL
Before disposing of batteries consult local and governmental regulatory requirements for proper disposal
procedure.
SPECIFIC SYSTEM WARNINGS
Below are some specific operating safety tips that should be strictly followed when operating a Flex
Mini system:
1.
Check the Status LED on the transmitter for any signs of low battery power.
2.
Check the Status LED on the transmitter for any signs of irregularities.
3.
Make sure the system is not set to the same channel as any other Flex Mini 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.
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June 2015
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1. GENERAL SYSTEM INFORMATION
1.1 TRANSMITTER
1.1.1 External Illustration
9
1.
2.
3.
4.
5.
2
1
4
3
6
5
8
7
Button #1 (PB1)
Button #2 (PB2)
Button #3 (PB3)
Button #4 (PB4)
Button #5 (PB5)
6.
7.
8.
9.
Button #6 (PB6)
Button #7 (PB7)
Button #8 (PB8)
Status LED
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1.1.2 Internal Illustration
9
10
2
1
4
3
11
6
5
8
7
12
13
1.
2.
3.
4.
5.
6.
7.
Button #1 (PB1)
Button #2 (PB2)
Button #3 (PB3)
Button #4 (PB4)
Button #5 (PB5)
Button #6 (PB6)
Button #7 (PB7)
8. Button #8 (PB8)
9. Status LED
10. RF + Encoder Board
11. Function Dip-switch
12. Programming Port
13. Battery Contacts
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1.2 RECEIVER
1.2.1 External Illustration
3
2
1
4
7
5
6
1.
2.
3.
4.
COM LED
Status LED
Power LED
Output Relays LED
5. System Information
6. Cord Grip
7. Mounting Bracket
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June 2015
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1.2.2 Internal Illustration
1. RF + Decoder Board
2. AC Line Filter + Relay Board
3. Power Transformer
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2. FUNCTION SETTINGS
2.1 TRANSMITTER
2.1.1 Channel Settings
Enter the transmitter function setting mode by moving the function dip-switch located inside the
battery compartment to the “on” position. Reinsert the two batteries and press PB1 to power up the
transmitter. At this point the Status LED will display a series of red, green, and orange blinks showing
the current software version. Then press and hold PB3 for up to 1.0 second to go into the transmitter
channel setting mode. At this point the Status LED will display a series of green and red blinks
showing the current system channel. A green blink represents the tens (+10) and a red blink
represents the units (+1). For example, one (1) green blink followed by five (5) red blinks is channel
15.
Now 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). For example, pressing PB2 two times and then PB1
four times will set the transmitter to channel 24.
NOTE: When selecting a new channel, make sure each button press does not exceed 3.0 seconds.
When finished the transmitter Status LED will display the newly selected channel. The newly selected
channel must be transferred to the receiver by pressing and holding PB3 for up to 10.0 seconds or
until the transmitter Status LED turns off, which indicates that the transferring process is completed.
Make sure the receiver power is turned on during the process. Exit the transmitter function setting
mode by removing the batteries and moving the function dip-switch back to the “Off” position.
NOTE: When the transmitter keypad is set to type 1 the receiver must be reset (turned off and back
on), or the channel setting process must be executed 10 minutes after receiver inactivity.
NOTE: When you are changing the transmitter channel you must also change the receiver channel at
the same time prior to exiting the transmitter function setting mode (see the instructions above). If you
exit the transmitter function setting mode without pressing PB3 for up to 10.0 seconds to transfer the
newly selected channel to the receiver, you will have to change the newly selected transmitter
channel back to its previous setting. This can be done by reentering the transmitter function setting
mode and then pressing and holding PB1 and PB3 at the same time for up to 2.0 seconds; this will
reset the newly selected channel back to the previous setting.
Alternately, perform the remote pairing process (RX to TX) described in Section 2.1.3 Remote Pairing;
this will transfer the receiver channel to the transmitter. Repeat the channel setting process again if
you would like to reselect a new channel.
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June 2015
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2.1.2 Keypad Type Settings
Enter the transmitter function setting mode by moving the function dip-switch located inside the
battery compartment to the “on” position. Reinsert the two batteries and press PB1 to power up the
transmitter. At this point the Status LED will display a series of red, green, and orange blinks showing
the current software version. Press and hold PB4 for up to 1.0 second to go into the keypad type
setting mode. At this point the Status LED will blink red, showing the current keypad type. A green
blink represents the tens (+10) and a red blink represents the units (+1). For example, two (2) red
blinks is keypad type 2.
Now select the new keypad type by pressing PB1 and PB2 on the transmitter. Press PB1 to
increment the units (+1) and PB2 to increment the tens (+10). For example, press PB1 two times for
keypad type 2 and three times for keypad type 3. The Status LED will display the newly selected
keypad type when finished. Exit transmitter function setting mode by taking out the batteries and
moving the function dip-switch back to “off” position.
NOTE: When selecting a new keypad type, make sure each button press does not exceed 3.0
seconds.
P B2
PB1
P B2
ON
OFF
PB4
PB3
PB4
PB3
PB4
PB3
P B6
PB5
P B6
PB5
P B6
PB5
P B8
PB7
P B8
PB7
P B8
PB7
Type 1
Type 2
START STOP
Type 3
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June 2015
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2.1.2.1 Keypad Overlay
When changing the keypad type setting, it is recommended to change the keypad overlay sticker on
the unit as well. This will ensure that the operator knows which buttons are the function buttons and
which buttons are used for either ON/OFF or START and STOP. The following procedure should be
used to change the keypad overlay. If the unit does not have an overlay, start at step 4.
1.
2.
3.
4.
5.
6.
Remove the old overlay.
Wipe the unit down with rubbing alcohol to remove any adhesive that is still on the unit.
Let the unit dry.
Remove the backing from the new overlay.
Align the overlay with the bottom of the inset for the keypad.
Slowly place the overlay over the buttons ensuring that the overlay makes contact around
each of the buttons.
7. Firmly press the entire overlay to ensure that it seals the unit to maintain sealing.
2.1.3 Remote Pairing
Enter the transmitter function setting mode by moving the function dip-switch
located inside the battery compartment to the “on” position. Reinsert the two
batteries and press PB1 to power up the transmitter. At this point the Status
LED will display a series of red, green, and orange blinks showing the current
software version. Then press and hold PB3 and PB4 at the same time for up
to 1.0 second to go into the remote pairing mode (Status LED orange and then
off).
TX to TX Pairing:
PB3
Output data – original transmitter
(Press and hold PB3)
PB4
Receiving data – new transmitter
(Press and hold PB4)
After entering the remote pairing mode, output data by pressing and holding PB3 on the original
transmitter and receive data to the new transmitter by pressing and holding PB4 at the same time.
The pairing is completed when the Status LED on the new transmitter (the unit receiving the data)
turns to constant green while the buttons are still pressed down. Exit the transmitter function setting
mode by taking out the batteries and move the function dipswitch on both transmitters back to the “off”
position.
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June 2015
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RX to TX Pairing:
PB4
Output data - receiver
(Press and hold PB1)
Receiving data – transmitter
(Press and hold PB4)
Via the Decoder Board
JP1 Open Method (via the decoder board): After entering the remote pairing mode, output receiver
data by pressing and holding PB1 located on the decoder board and receive data by pressing and
holding PB4 on the transmitter at the same time. The pairing is completed when the transmitter
Status LED turns to constant green while both buttons are still pressed down. Exit the transmitter
function setting mode by taking the batteries out of the transmitter and move the function dipswitch
back to the “off” position.
PB4
Output data - receiver
(Press and hold the Pairing button)
Receiving data – transmitter
(Press and hold PB4)
Via the External Pairing Button
JP1 Open Method (via the external Pairing button): After entering the remote pairing mode, output
receiver data by pressing and holding the Pairing button located on the receiver cover and receive
data by pressing and holding PB4 on the transmitter at the same time. The pairing is completed when
the transmitter Status LED turns to constant green while both buttons are still pressed down. Exit the
transmitter function setting mode by taking the batteries out of the transmitter and move the function
dipswitch back to the “off” position.
JP1 Short Method (does not require the decoder board or the external Pairing button): After
entering the remote pairing mode, press PB1 on the transmitter and then press and hold PB3 for up to
5.0 seconds to activate receiver data output mode (Status LED green blinks). Then press and hold
PB4 on the transmitter until the Status LED turns to constant green (RX to TX pairing complete). Exit
the transmitter function setting mode by taking the batteries out of the transmitter and move the
function dip-switch back to the “off” position. Make sure the RX to TX pairing process is executed
within a distance of 10 meters from one another.
NOTE: When the transmitter keypad is set to type 1 while performing RX to TX remote pairing, the
receiver must be reset (turn off and back on) or the RX to TX remote pairing must be executed 5
minutes after receiver inactivity.
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June 2015
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2.2 RECEIVER
2.2.1 Dipswitch Settings
Top position
“1”
“0”
Bottom position
1 2 3 4 5 6 7 8
ON
1
ON
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
Dipswitch #1 (right):
Position
Dip 1
Dip 2
Dip 3
Dip 4
Dip 5
Dip 6
Dip 7
Dip 8
Set to “0”
PB1
Normal
PB2
Normal
PB3
Normal
PB4
Normal
PB5
Normal
PB6
Normal
PB7
Normal
PB8
Normal
Set to “1”
PB1
Toggled
PB2
Toggled
PB3
Toggled
PB4
Toggled
PB5
Toggled
PB6
Toggled
PB7
Toggled
PB8
Toggled
Toggled functions maintain contact when transmitter power is turned off (keypad type 2) or Stop button is pressed (keypad type 3).
Dipswitch #2 (left):
Position
Dip 1
Dip 2
Dip 3
Dip 4
Dip 5
Dip 6
Dip 7
Dip 8
Set to “1”
PB1&2
On & Off
PB3&4
On & Off
PB5&6
On & Off
PB7&8
On & Off
PB1&2
Interlocked
PB3&4
Interlocked
PB5&6
Interlocked
PB7&8
Interlocked
Set to “0”: According to dip-switch #1 setting.
Dip 5~8 set to “1”: Button pair interlocked. When set to interlocked pair you must reconfigure dip-switch #1 below.
On & Off function turns to “Off” when transmitter power is turned off (keypad type 2) or Stop button is pressed (keypad type 3).
Dipswitch #1 (right) - Normal and Toggled Interlocked Settings:
Position
Dip 1&2
Dip 3&4
Dip 5&6
Dip 7&8
Set to “00”
PB1&2 Normal/Normal
Interlocked
PB3&4 Normal/Normal
Interlocked
PB5&6 Normal/Normal
Interlocked
PB7&8 Normal/Normal
Interlocked
Set to “01”
PB1&2 Toggled/Toggled
Interlocked
PB3&4 Toggled/Toggled
Interlocked
PB5&6 Toggled/Toggled
Interlocked
PB7&8 Toggled/Toggled
Interlocked
Dipswitch #2 (left) - ID Function Settings (keypad type 3):
Position
Function
Position
Function
Set to “0001001”
K2 output relay closes when
PB7 & PB8 is pressed.
Set to “0001101”
K2 output relay closes when
PB3 & PB4 or PB7 & PB8 is pressed.
Set to “0001010”
K2 output relay closes when
PB5 & PB6 is pressed.
Set to “0001110”
K2 output relay closes when
PB3 ~ PB6 is pressed.
Set to “0001011”
K2 output relay closes when
PB5 ~ PB8 is pressed.
Set to “0001111”
K2 output relay closes when
PB3 ~ PB8 is pressed.
Set to “0001100”
K2 output relay closes when
PB3 & PB4 is pressed.
When a button pair is set to the ID function the corresponding button setting on dipswitch #1 must set to “0”.
When set to ID function the START/AUX function on keypad type 3 is disabled (auxiliary function replaced by ID function).
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June 2015
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2.2.2 Jumper Settings (for units with the external Pairing
button)
JP1 Open
Remote pairing function (press Pairing button required).
JP1 Short
Remote pairing function (press Pairing button not required).
JP2 Open
System normal.
JP2 Short
Display receiver software version.
JP3 Open
Normal toggled function set on the dip-switches.
JP3 Short
All toggled functions set on the dip-switches deactivates
when shutting off the transmitter power (keypad type 2)
and when the Stop button is pressed (keypad type 3).
JP4 ~ JP8
Reserved for future functions.
2.2.3 External Programming (for units with the external Pairing
button)
Other settings not listed in this manual can be programmed via the external programmer unit. Please
contact Magnetek representatives in your area for more details.
Transmitter
Receiver
Other available functions set via external programmer unit:
1) On & Off function not affected by the transmitter power On/Off and Stop command.
2) On + Start / Off + Start function (keypad type 3 only).
2.2.4 Fuse Ratings
Fuse #
110~120VAC
220~240VAC
380~400VAC
410~460VAC
24VAC
42 & 48VAC
9~36VDC
F2 & F3
5.0A
5.0A
5.0A
5.0A
5.0A
5.0A
5.0A
F1
0.5A
0.5A
0.5A
0.5A
1.0A
1.0A
2.0A
Flex Mini System Instruction Manual
June 2015
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2.2.5 Using External Antenna (optional)
Please make sure to set the jumper to “EXT” when external antenna is connected.
INT
Internal antenna used
EXT
External antenna used
Flex Mini System Instruction Manual
June 2015
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3. RECEVIER INSTALLATION
*
( ) For keypad type #2 and type #3 setups.
*
For 9~36VDC power supply, wire #1 corresponds to the negative charge (-) and wire
#3 corresponds to the positive charge (+); wire #2 is for GROUND.
Flex Mini System Instruction Manual
June 2015
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Secure the mounting bracket to the wall or equipment via two screws (not provided with the system).
Slide down the receiver along the guided track to secure the receiver to the mounting bracket (see
below). Make sure the screws are tightened after installation.
WALL
Remove the receiver by pressing down the bracket release and pull the receiver upward until it clears
the guided track (see below).
WALL
Remove the two components (shown on the right with
arrows pointing to them) when the 380~400VAC or 410~460VAC
power transformer is used.
Flex Mini System Instruction Manual
June 2015
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4. OPERATING PROCEDURE
4.1 GENERAL OPERATING PROCEDURE
Keypad Type 1:
The transmitter is powered on and operated by pressing any button on the
keypad (green blinks on Status LED). The transmitter goes into sleep mode
after 5 minutes of inactivity (buttons not pressed). Press any button to wake
up the transmitter and continue operation.
Keypad Type 2:
P B2
PB1
PB4
PB3
P B6
PB5
P B8
PB7
Type 1
The transmitter is powered on by pressing the On/Off button once for up to
2.0 seconds (green on Status LED); the receiver main is also activated at the
same time. The Status LED will blink green every 4 seconds thereafter for up
to 5 minutes when no buttons are pressed (transmitter standby). After 5
minutes the transmitter will go into sleep mode. Press the On/Off button for
up to 1.0 second to wake up the transmitter and continue operation. Shut off
the transmitter power by pressing the On/Off button for up to 2.0 seconds
(red on Status LED and then off); the receiver main is deactivated at the
same time. The system will not work when pressing any buttons prior to
initiating the On/Off command (Status LED blinks 2 red).
P B2
ON
OF F
PB4
PB3
P B6
PB5
P B8
PB7
Type 2
Keypad Type 3:
The transmitter is powered on by pressing the Start button once for up to 2.0
seconds (green on Status LED); the receiver main is also activated at the
same time. The Start button becomes an auxiliary function thereafter. The
Status LED will blink green every 4 seconds thereafter for up to 5 minutes
when no buttons are pressed (transmitter standby). After 5 minutes the
transmitter will go into sleep mode. Press the Start button again for up to 1.0
second to wake up the transmitter and continue operation. Shut off the
transmitter power by pressing the Stop button for up to 2.0 seconds (red on
Status LED and then off); the receiver main is deactivated at the same time.
The system will not work when pressing any buttons prior to initiating the
Start command (Status LED blinks 2 red).
START STOP
PB4
PB3
P B6
PB5
P B8
PB7
Type 3
4.2 CHANGING TRANSMITTER BATTERIES
Change the transmitter batteries (“AA” alkaline battery x 2) by unscrewing the battery cover located on
the backside of the transmitter counterclockwise. During battery installation make sure the batteries
are installed correctly, with “+” to “+” charge and “–” to “–” charge. Also make sure the screw is
tightened after battery installation to avoid water, moisture, dirt, grease, or other liquid penetration.
Flex Mini System Instruction Manual
June 2015
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5. STATUS & WARNINGS
5.1 TRANSMITTER STATUS LIGHT INDICATIONS
Type
Display Type
Indication
1
1 red blink
Transmitter low battery
Change battery immediately
2
Constant red
Transmitter power off due to low battery condition
3
2 red blinks
Button jammed or defective
(for keypad type 2 & type 3 setups only)
4
Green blinks
Transmission in progress
5
1 green blink every 4 seconds
Transmitter on standby
(for keypad type 2 & type 3 setups only)
Note on Type 3 above: A jammed or defected button is shown by 2 red blinks on the Status LED when pressed. For
example, when 2 red blinks are shown on the Status LED, press each button, one at a time, to see which one is jammed
or defective. A good working button will not display any lights on the Status LED when pressed, while a jammed or
defective button will blink red twice when pressed.
5.2 RECEIVER STATUS LIGHT INDICATIONS
Type
Display Type
Indication
1
Fast green blinks
Decoding in process
2
Slow green blinks
Decoding on standby
3
Constant red blinks
Incorrect serial Number/ID code received
4
Constant red
Receiver Low voltage
5.3 RECEIVER COM LIGHT INDICATIONS
Type
Display Type
Indication
1
Constant red
Power to the relay board
2
Off
No power to the relay board
5.4 RECEIVER POWER LIGHT INDICATIONS
Type
Display Type
Indication
1
Constant red
Power to the receiver
2
Off
No power to the receiver
Flex Mini System Instruction Manual
June 2015
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6. SYSTEM SPECIFICATIONS
Frequency Range
:
433~434MHz
Frequency Deviation
:
50 KHz
Number of Channels
:
32 channels
Modulation
:
Digital Frequency Modulation based
on Manchester Code, 24bit address,
and 8bit CRC Parity Check.
Encoder & Decoder
:
Microprocessor-controlled
Transmitting Range
:
>50 Meters / 164 Feet
Frequency Control
:
Synthesized PLL
Receiver Sensitivity
:
-104dBm
Antenna Impedance
:
50ohms
Responding Time
:
50mS
Transmitting Power
:
1mW
Enclosure Type
:
NEMA4
Enclosure Rating
:
IP66
Output Contact Rating
:
250V @ 8 Amps
Transmitter Operating Voltage
:
3.0VDC
Transmitter Power Consumption
:
5~22mA
Receiver Power Consumption
:
40~220mA
Receiver Supply Voltage
:
9~36VDC
24VAC
42VAC
48VAC
110~120VAC
220~240VAC
380~400VAC
410~460VAC
Operating Temperature
:
-25°C ~ 75°C / -13°F ~ 167
Transmitter Dimension
:
120mm (L) x 54mm (W) x 28mm (H)
Receiver Dimension
:
170mm (L) x 106mm (W) x 69mm (H)
Transmitter Weight
:
160g / 5.6oz (includes batteries)
Receiver Weight
:
1.0kg/ 2.2lb (includes output cable)
F
June 2015
Page 25 of 25
Flex Mini System Instruction Manual
Enrange™ Flex Mini
Technical Specifications
General Flex Series Specifications
Other Features
 Universal spare transmitter
 Direction and compass labels standard (Custom labeling
available)
 Wrist strap
 Magnet (5.0kg / 11.0lb)
 Belt clip
Temperature Range:
 -13°F to 167°F (-25°C to 75°C)
Environmental Protection:
 IP-66/NEMA 4X
Material Type:
 Glass reinforced nylon
Receiver Specification
Test & Certifications:
 FCC Approved Part 15
 IEC 68-2-34 Random Vibration
 IEC 68-2-27 Shock Testing
 IEC 68-2-31 Drop & Topple
Dimensions:
 Approximately 6.7" x 4.2" x 2.7" (170 x 106 x 69 mm)
Mounting Type:
 Panel mount
RF Operation Range:
 Non-Licensed Part 15
Up to 200 feet (60.96 m)
Frequency Range:
 Non-Licensed Part 15
433-434 MHz
Output Power:
 Non-Licensed Part 15
Less than 1 mW
RF Channels
 Non-Licensed Part 15
32 channels
Power Consumption:
 40-220mA
Transmitter Specification
Weight:
 Approximately 5.6 oz (160 g) – including batteries
Dimensions:
 Approximately 4.7" x 2.1" x 1.1" (120 x 54 x 28 mm)
Power:
 2 AA Batteries
 90+ operating hours continuous operation
Pushbuttons:
Input Voltage:
 110 Vac
 24 Vac
 42 Vac
 48 Vac
 220 Vac
 380 Vac
 410 Vac
 12/24 Vdc (Standard)
Output Type:
 8 mechanical relays (Normally Open)
Relay Rating:
 250 Vac or 30 Vdc @ 8A, fused at 5A for all outputs
combined
 100,000 cycles
Antenna:
 Internal
Diagnostics:
 LED error codes
 One step (speed)
 Mechanical switches
Other Features
 Pre-wired receiver with 6’ cable
 Figure configurable outputs
Antenna:
 Internal
Diagnostics:
 LED error codes
P.O. Box 13615 Milwaukee, WI 53213 Toll‐Free Phone 800.288.8178 Toll‐Free Fax 800.298.3503 N49 W13650 Campbell Drive Menomonee Falls, WI 53051 Phone 262.783.3500 Fax 262.783.3510 Canada Facility
4090B Sladeview Crescent Mississauga, Ontario L5L 5Y5 Canada Toll Free Phone: 800.792.7253 Fax: 905.8281526 Magnetek (UK) Ltd.
www.magnetekmobilehydraulic.com
Unit 3, Bedford Business Centre Mile Road Brochure No. Enrange Flex Mini Bedford, MK42 9TW UK Tech Specs Phone: +44 (0) 1234 349191 Fax: +44 (0) 1234 268955 Enrange™ Flex Mini
Technical Specifications
MECHANICAL LAYOUTS
Flex Mini Transmitter
Flex Mini Receiver
P.O. Box 13615 Milwaukee, WI 53213 Toll‐Free Phone 800.288.8178 Toll‐Free Fax 800.298.3503 N49 W13650 Campbell Drive Menomonee Falls, WI 53051 Phone 262.783.3500 Fax 262.783.3510 Canada Facility
4090B Sladeview Crescent Mississauga, Ontario L5L 5Y5 Canada Toll Free Phone: 800.792.7253 Fax: 905.8281526 Magnetek (UK) Ltd.
www.magnetekmobilehydraulic.com
Unit 3, Bedford Business Centre Mile Road Brochure No. Enrange Flex Mini Bedford, MK42 9TW UK Tech Specs Phone: +44 (0) 1234 349191 Fax: +44 (0) 1234 268955