Magnetek Flex PRO Flex M Radio Control System Instruction Manual
Below you will find brief information for Radio Control System Flex PRO Flex M. The Flex M system comprises of a RF/CPU module and a power supply module with application-specific add-on cards in-between the CPU module and power supply module. The Flex RF/CPU Module is the main module that receives radio signals from a paired transmitter and interprets those signals into the appropriate response from the attached I/O modules. There is one RF/CPU module in the Flex M System.
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Flex PRO / Flex M Pre-Engineered
Radio Control System
Part Number: 191-00195-1200
April 2012
© 2012 Magnetek Material Handling
TABLE OF CONTENTS
PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED CRANES ..................................... 8
SAFETY INFORMATION AND RECOMMENDED TRAINING FOR RADIO CONTROLLED
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
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10. RECEIVER CHANNEL CONFIGURATION SETTINGS (BANK 2 ON RF/CPU MODULE) .............. 32
CHANNEL DIP SWITCH SETTINGS FOR 433MH Z PART 15, VERSION 2 RF/CPU MODULE (25-02-
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PRODUCT MANUAL SAFETY INFORMATION
Magnetek, Inc. (Magnetek) offers a broad range of radio remote control products, control products and adjustable frequency drives, and industrial braking systems for material handling applications. This manual has been prepared by Magnetek to provide information and recommendations for the installation, use, operation and service of 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.
WARRANTY INFORMATION
For information on Magnetek’s product warranties by product type, please visit www.magnetekmh.com.
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Your New Flex PRO/Flex M Radio
Control System
Thank you for your purchase of Magnetek’s Enrange
®
brand Flex PRO/Flex M Radio Remote Equipment
Control. Magnetek has set a whole new standard in radio-remote performance, dependability, and value with this line of modular receivers.
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
Phone: 1.800.288.8178
Fax: 1.800.298.3503
Magnetek, Inc. has additional satellite locations for Canada and the United States. For more information, please visit http://www.magnetekmh.com.
©2012 MAGNETEK
All rights reserved. This notice applies to all copyrighted materials included with this product, including, but not limited to, this manual and software embodied within the product. This manual is intended for the sole use of the person(s) 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.
Flex PRO / Flex M Pre-Engineered Radio Control System Instruction Manual
April 2012
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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 standard-equipped accessories such as a 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:
• 32 user-programmable channels – Advanced synthesized RF controls with 32 built-in channels; there are no more fixed channel and fragile quartz crystals to break.
• Over one million unique ID codes (20bit) – Each and every Flex system has its own unique ID code; no repeats.
• Advanced controls – The Flex system utilizes advanced microprocessor controls with 16bit CRC which provides 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 are rated for more than one million press cycles.
• Low power consumption – Requires only two “AA” Alkaline batteries for more than 100 hours of operating time between replacements.
• Ultra-durable nylon and fiberglass composite enclosures – Highly resistant to breakage and deformation even in the most abusive environments.
• Full compliance – All systems are fully compliant with the FCC Part-15 Rules and Industry
Canada Specifications (IC).
• System Versatility – The Flex PRO/Flex M Radio Control Systems are able to control up to 4 motions (or 3 motions with A/B Select) with the Flex 8 PRO transmitter or up to 6 motions (or 5 motions with A/B Select) with the Flex 12 PRO transmitter.
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2. RADIO CONTROLLED SAFETY
2.1. 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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2.2. 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 AND DAMAGE TO EQUIPMENT.
2.3. 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.
2.4. 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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2.5. 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
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•
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
WARNING
THE OPERATOR SHOULD NOT ATTEMPT TO REPAIR ANY RADIO CONTROLLER. IF ANY PRODUCT
PERFORMANCE OR SAFETY CONCERNS ARE OBSERVED, THE EQUIPMENT SHOULD IMMEDIATELY BE
TAKEN OUT OF SERVICE AND BE REPORTED TO THE SUPERVISOR. DAMAGED AND INOPERABLE RADIO
CONTROLLER EQUIPMENT SHOULD BE RETURNED TO MAGNETEK FOR EVALUATION AND REPAIR.
FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO
EQUIPMENT.
2.6. 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.
2.7. 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.
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2.8. BATTERIES
WARNING
KNOW AND FOLLOW PROPER BATTERY HANDING, CHARING, AND DISPOSAL PROCEDURES. IMPROPER
BATTERY PROCEDURES CAN CAUSE BATTERIES TO EXPLODE OR DO OTHER SERIOUS DAMAGE. FAILURE
TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
2.9. 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 intrinsically safe batteries.
Keep the battery pack environment cool during charging operation and storage (i.e., not in direct sunlight or close to a heating source).
2.10. 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 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.
2.11. BATTERY DISPOSAL
Before disposing of batteries consult local and governmental regulatory requirements for proper disposal procedure.
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2.12. SPECIFIC SYSTEM WARNINGS
Below are some specific operating safety tips that should be strictly followed when operating a Flex Pro system:
1. Check the Status LED on the transmitter for any signs of low battery power (refer to Section
11.1).
2. Check the Status LED on the transmitter for any signs of irregularities (refer to Section 11.1).
3. Make sure the system is not set to the same channel as any other Flex systems in use within a distance of 300 meters (900 feet).
4. Never operate equipment with two transmitter handsets at the same time unless they are programmed to do so.
2.13. FLEX M RECEIVER INSTALLATION
WARNING
BEFORE OPERATING THE RECEIVER FAMILIARIZE YOURSELF WITH ALL SAFETY INFORMATION IN THIS
MANUAL, APPROPRIATE MANUAL SUPPLEMENTS AND ANY OTHER LOCAL, STATE, OR FEDERAL RULES OR
REGULATIONS ALREADY IN EXISTENCE. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS
INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
2.14. PRE-INSTALLATION
1. Transmitter and receiver access code and channel must match before the system will communicate.
2. Be aware of other radio channels in the surrounding area - set your system to a unique channel.
3. Make sure that your equipment is working properly in manual mode prior to system installation.
4. Make sure the power to the receiver is the correct voltage.
5. Disconnect equipment power prior to system installation.
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3. GENERAL TRANSMITTER
INFORMATION
3.1. EXTERNAL ILLUSTRATION (PRO 12 CONFIGURATION)
Figure 1 Figure 2
E. Emergency Stop Button
S. Removable Power Key Switch
1. Push Button #1
2. Push Button #2
3. Push Button #3
4. Push Button #4
6. Push Button #6
7. Push Button #7
8. Push Button #8
9. Push Button #9
10. Push Button #10
11. Push Button #11
SC. Strap Ring
SN. System Information
RN. System Channel
MN. Machine Number
FC. FCC Information
5. Push Button #5 12. Push Button #12
NOTES:
1. Pushbuttons #9 - #12 are not present on the Flex 8 PRO Transmitter
2. Pushbutton #7 on the Flex 8PRO and pushbutton #11 on the Flex 12 PRO can be set to
“A / B / BOTH” Select (via dip switch; see Section 4.3)
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3.2. INTERNAL ILLUSTRATION (PRO 12 CONFIGURATION)
1.
2.
3.
4.
Figure 3
Encoder Board
Aerial Antenna
Transmitting Module
Status LED Display
5 . Function LED Displays
NOTE: Flex PRO 8 Module will differ slightly
6.
7.
8.
Figure 4
I-CHIP
Dip-Switch
Battery Contact Mechanism
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3.3. TYPES OF BUTTONS
The buttons used on the Flex Pro are fully proportional, stepless push buttons with an output that varies
0-100% (based on how far the button is depressed). Please consult the factory for more information.
3.4. ADJUSTABLE SPEED CONTROL
The proportional buttons normally operate on a scale from 0-100%, but can also be scaled down to operate linearly from 0-25% over the full motion of the button. This gives the user more control over lower speeds. To adjust the speed control settings, press and hold the Start button, then press push button 1 or push button 2 to decrement/increment the range percentage. The red LEDs, which indicate the Speed
Setting, will then change to reflect the current setting.
Start +
PB1
Speed control setting
Decrement Speed Control
PB2 Increment Speed Control
Figure 5 Figure 6
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4. DIP SWITCH SETTINGS
4.1. SYSTEM CHANNEL SETTINGS
Set the transmitter channel by adjusting the channel dip-switch located on the backside of the transmitter encoder board (refer to Figure 7 below). Only the first five (5) positions of the dip-switch are used for channel programming (refer to Figure 8 below). The system channels table (Section 5) illustrates which dip-switch setting corresponds to which channel. Once the transmitter channel is altered, you must set up the receiver to recognize the transmitters on its new channel.
Top slot → “1”
Bottom slot → “0”
Figure 7 Figure 8
The above dip-switch setting “1 0 0 1 0” corresponds to “channel 19” in the system channels table
(Section 5).
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4.2. INACTIVITY TIME OUT TIMER
Bits 6 and 7 on the dip-switch allows the user to define a time after which, if no buttons on the transmitter are pressed, the Flex Pro will send an OFF command to the receiver and power down. To restart, the user must turn the On/Off/Start switch to the Off position, then back to On again to resume operation.
Time Out
Dip-switch
Setting
5 minutes
10 minutes
15 minutes
Never shut off
01
10
11
00
Figure 9
4.3. A/B/BOTH SELECT
Bit 8 on the dip-switch allows the user to set the lower left pushbutton (PB7 on the Flex 8 PRO, PB11 on the Flex 12 PRO) into an A / B / BOTH Select button. When the A / B / BOTH Select button is enabled, it can be used to toggle through the desired outputs as follows: A > B > BOTH > A ...
A / B / BOTH
Enabled
Disabled
Dip-switch
Setting
1
0
Figure 10
NOTE: When A/B Select function is Enabled, A/B LEDs will be OFF at initial startup, but will remain ON
(A, B, or BOTH) once selected. When A/B Select function is disabled, A/B LEDs will remain OFF.
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5. SYSTEM CHANNEL TABLE
Channel
01
02
03
04
05
06
07
12
13
14
15
16
08
09
10
11
Frequency
433.000MHZ
433.050MHZ
433.100MHZ
433.150MHZ
433.200MHZ
433.250MHZ
433.300MHZ
433.350MHZ
433.400MHZ
433.450MHZ
433.500MHZ
433.550MHZ
433.600MHZ
433.650MHZ
433.700MHZ
433.750MHZ
Dip-switch
Setting
00000
00001
00010
00011
00100
00101
00110
00111
01000
01001
01010
01011
01100
01101
01110
01111
Channel
17
18
19
20
21
22
23
28
29
30
31
32
24
25
26
27
Frequency
433.800MHZ
433.850MHZ
433.900MHZ
433.950MHZ
434.000MHZ
434.050MHZ
434.100MHZ
434.150MHZ
434.200MHZ
434.250MHZ
434.300MHZ
434.350MHZ
434.400MHZ
434.450MHZ
434.500MHZ
434.550MHZ
Dip-switch
Setting
10000
10001
10010
10011
10100
10101
10110
10111
11000
11001
11010
11011
11100
11101
11110
11111
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6. OPERATING PROCEDURE
6.1. GENERAL OPERATING PROCEDURE
1. 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.
Figure 11
2. 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 the “On” position.
Figure 12 Figure 13
3. After turning on the transmitter power, check the Status LED on the transmitter handset for any sign of system irregularities (refer to Section 11.1). If the system is normal the Status LED will light up green for two (2) seconds, then slowly flash green.
4. If there are no signs of any system irregularities, then rotate the power key further clockwise to the “Start” position for up to 2 seconds. This will activate the receiver E-Stop. Thereafter, the same “Start” position will become an auxiliary function with momentary contact.
Figure 14
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5. Now press any push button on the transmitter handset to operate the equipment. When a button is pressed, the Status LED will flash orange with a variable speed dependent on how far the button is pressed. The further a button is pressed, the faster the LED will flash. When no buttons are pressed, the
Status LED will slowly blink green.
6. In case of an emergency, pressing down on the red emergency stop button will immediately disconnect the receiver E-Stop and turn off the unit. To reset the emergency stop button just rotate the red button either clockwise or counter-clockwise and then cycle power to the unit.
7. After a period of inactivity (push button not pressed) defined by the dip switch, the receiver E-Stop will be disconnected and the unit must cycle power before turning on again.
8. Turn off the transmitter power by rotating the power key counter-clockwise to the “Off” position
(Status LED becomes a solid red for 4 seconds). This will disconnect the transmitter power and the receiver E-Stop altogether. Turn it further counter-clockwise to release the key.
6.2. CHANGING TRANSMITTER BATTERIES
Change the transmitter batteries by unscrewing the battery cover located on the backside of the transmitter (refer to Figures 15 and 16 below). During battery installation make sure that the 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.
↓
2
1
Figure 15 Figure 16
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7.0 RECEIVER MECHANICAL
DRAWINGS
7.1. MECHANICAL LAYOUTS
Figure 17: Mechanical Layout (Flex M-24)
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Figure 18: Mechanical Layout (Flex M-32)
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Figure 19: Example of Flex M Receivers Mounted in an Enclosure
7.2. RECEIVER INSTALLATION
1. Be sure to mount the receiver antenna in direct line-of-sight of the operator and free from all obstructions.
2. Do not mount the receiver near high levels of electric noise, such as an unshielded variable frequency drive, as it may cause minor interference. When mounting the Flex M near unshielded variable frequency drive, Magnetek typically recommends that the Flex M and all antenna cable routing be
mounted a minimum of 24 inches from all unshielded variable frequency drives and cables.
3. Allow adequate room for mounting the receiver. Make sure to allow a minimum of 5” between the connector and nearest surface to allow for cable harness connections.
4. For best reception and to help protect connectors from moisture and water damage, mount the receiver in an upright position. Mount with back flush against a flat surface to protect vents from spray.
5. If obstructions cannot be cleared, or the unit must be mounted inside a metal enclosure, the remote antenna should be used (see Figure 19).
6. Do not enclose the antenna in steel. For the best reception, keep all metal objects away from the antenna. Consult the factory for more information regarding your application.
7. The supply power to the Flex M system must have a master disconnect and should be fused.
8. The Flex M modules are installed on a 35mm din rail. To install the individual modules on the din rail, hook the bottom of the module on the din rail and swing the top of the module to the rail until a click is heard or felt.
9. After the modules are placed on the rail, they are slid together so they nest together. Rail clamps are suggested to prevent the module bundle from sliding freely on the rail.
10. Modules MUST be installed so that the RF/CPU module is on the left end of the rail and the power supply module is on the right end of the rail.
NOTE: Magnetek strongly recommends the use of external fuses and circuit disconnects for all Flex
Modules. Consult factory for more information.
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7.3. REMOVAL
1. To remove modules from the rail for service, first ensure all power to the Flex M modules has been turned off and proper lockout/tagout procedures have been followed.
2. Remove one end rail clamp and un-nest the module that you wish to remove by separating it from the others on the rail.
3. Use a slotted screwdriver to lift the exposed metal tab/ring on the top of the module. Swing the module down away from the top tab/ring and unhook from the rail.
4. The PCB from any module can be removed from its housing by pressing in both tabs first (tabs are on the front and back sides of the housing); then the top housing and PCB can be removed from the lower housing (see Figure 20 for details).
Figure 20: Flex M Housing Removal Detail
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8. NORMAL OPERATION
During the operation of the receiver, following the LED indicators will allow observation of the status of the
Flex M receiver.
8.1. POWER SUPPLY MODULE
When the Flex M system has power supplied, the two LEDs on the power supply module should be lit and solid.
+5VDC CPU – indicates that +5VDC power is going to the CPU
+5VDC RELAY – indicates that +5VDC power is going to the RELAY modules
8.2. RF/CPU MODULE
When the Flex M system is supplying power to the RF/CPU module, there is a series of LEDs that will indicate the RF/CPU module’s status.
WDG/ONLINE LED:
- Solid indicates RF communication with transmitter
- 1 Blink indicates normal operating WDG
- 2 Blinks indicates RF communication loss with transmitter
- 3 Blinks indicates read/write error to an attached Flex M module
RF MSG LED:
- Fast Blinks indicates radio frequency messages received (typical is 4 to 10 messages per second). This confirms communication between transmitter and receiver
- 3 Steady Blinks indicates read/write error to an attached Flex M module
- 4 Steady Blinks indicates an internal radio error
RF SIGNAL LED – measures the strength of the RF communication signal from the transmitter
8.3. RELAY MODULE(S)
When the Flex M system is supplying power to the Relay module, there is an LED that indicates the power and communication status of the Relay module.
OK LED – Solid indicates module communication with system is good
- 3 Blinks indicates read/write error to attached CPU
Additionally, there are 8 LEDs labeled 1 through 8 on the Relay module. When the LED is on, this indicates that the relay is closed/activated.
8.4. ANALOG I/O MODULE(S)
When the Flex M system is supplying power to the Analog I/O module, there is an LED that indicates the power and communication status of the Relay module.
OK LED – Solid indicates module communication with system is good
- 3 Blinks indicates read/write error to attached CPU
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Additionally, there are 8 LEDs labeled 1 through 8 on the Analog I/O module. When the LED is on, this indicates that the module is sending/receiving a signal on that input or output.
LED1 = Analog Output 1 is Active (non-zero)
LED2 = Analog Output 2 is Active (non-zero)
LED3 = Analog Output 3 is Active (non-zero)
LED4 = Analog Output 4 is Active (non-zero)
LED5 = Analog Input 1 is Active (non-zero)
LED6 = Analog Input 2 is Active (non-zero)
LED7 = Analog Input 3 is Active (non-zero)
LED8 = Analog Input 4 is Active (non-zero)
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9. FLEX MODULE TYPES
The Flex M system comprises of a RF/CPU module and a power supply module with application-specific add-on cards in-between the CPU module and power supply module.
9.1. FLEX RF/CPU MODULE
The Flex RF/CPU Module is the main module that receives radio signals from a paired transmitter and interprets those signals into the appropriate response from the attached I/O modules. There is one
RF/CPU module in the Flex M System.
Figure 21: RF/CPU Module Detail View
Bank 1 Dip 1 on the dipswitches is used to set the style of transmitter being used. See chart below for proper settings.
BUTTON SETTING
Dip-switch
Setting
12-Button 1
8-Button 0
RF/CPU MODULE
25-02-074-816E 433MHz Part 15, version 2 RF/CPU Module
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9.2. FLEX M POWER SUPPLY MODULE
The Flex M Power Supply Module converts the supply power to 5VDC power for all the attached Flex M modules. This power module has a maximum output supply current of 1000mA. There is one Power
Supply Module in the Flex M system.
Not Used
Not Used
Not Used
GND
Figure 22: Power Supply Module Detail View
120VAC (L)
120VAC (L)
120VAC (N)
120VAC (N)
Not Used
Not Used
Not Used
GND
(+) VDC
(+) VDC
(-) COM
(-) COM
Figure 23: Typical 120VAC Power Wiring Figure 24: Typical VDC Power Wiring
NOTES:
1. Although the power module has built-in protection, Magnetek strongly recommends the use of external fuses and circuit disconnects for all Flex modules.
2. The built-in fuse is not user serviceable but can be checked if troubleshooting. To check the fuse, remove the power module from the din rail as described in Section 7.2. After removing the module from the din rail, press in the tabs as noted above to remove the PCB from the housing.
The fuse is location is shown in the PCB view above. Use a multimeter to check for continuity across the fuse. If the fuse is blown, contact Magnetek to send the module in for service.
3. The total system Current Consumption should not exceed the Maximum Output Supply Current of the power supply module. If additional supply current is required, contact the factory for a custom solution.
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Description
POWER SUPPLY MODULE OPTIONS
Max Output Current Minimum
Transformer Power
Rating
Part Number
120VAC Power Supply
Module
9-18 VDC @1.5A
Power Supply Module
15VA
25VA
1000mA
1500mA
25-02-074-804E
25-02-074-810E
9-36VDC Power Supply
Module
15VA 1000mA
25-02-074-820E
9.3. FLEX M RELAY MODULE
The Flex M Relay module allows the control of high current power (up to 5A) for attached equipment through 8 relay outputs. Four relays have a common power input and four relays have individually separate power inputs. The relay module number is set by the rotary switch located on the lower left corner of the board.
Figure 25: Relay Module Detail View
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Relay 8
Input Power
Relay 7
Input Power
Relay 6
Input Power
Relay 5
Input Power
Relays 1-4
Input Power
Relay Output 8
Relay Output 7
Relay Output 6
Relay Output 5
Relay Output 4
Relay Output 3
Relay Output 2
Relay Output 1
Figure 26: Typical Relay Wiring
9.4. FLEX M ANALOG I/O MODULE
Outputs: The four analog output signals are able to send voltage signals from 0 to +/-10VDC, at an 8bit resolution. These outputs are for reference voltage only, so each one can only supply 20mA of current.
The outputs share a common ground reference, which is isolated from the Flex M system ground and any additional I/O card output ground. These outputs can be preconfigured at the factory for different voltage ranges (ex. 0-5VDC, or 3-6-9VDC).
Inputs: The four analog input signals are able to receive voltage signals from 0 to +10VDC, at an 8bit resolution. The input impedance is 20K for these inputs. The inputs share a common ground reference, which is shared with the Flex M system ground.
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Figure 27: Analog I/O Module Detail View
Analog Input
Common
Analog Output
Common
Figure 28: Typical Analog I/O Wiring
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10. RECEIVER CHANNEL
CONFIGURATION SETTINGS
(Bank 2 on RF/CPU Module)
The channel can be set on the RF/CPU module via the Bank 2 dip switches. The following shows the channels or protocols available for each RF/CPU Module option.
NOTE: See Section 7.2 for instructions on how to remove the CPU/RF module from the din rail and how to remove the PCB from the module housing.
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10.1. CHANNEL DIP SWITCH SETTINGS FOR 433MHz PART 15, version 2 RF/CPU MODULE (25-02-
074-816E)
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10.2. FLEX M 24 AND 32 RELAY PRE-ENGINEERED WIRING
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10.3. FCC STATEMENTS
Compliance Statement (Part 15.19)
This device complies with Part 15 of FCC rules.
Operation is subject to the following two conditions:
1. This device may not cause harmful interference, and
2. This device must accept any interference received, including interference that may cause undesired operation.
Warning (Part 15.21)
Changes or modifications not expressly approved by the party responsible for compliance should void the user’s authority to operate the equipment.
This portable transmitter with its antenna complies with FCC’s RF exposure limits for general population/uncontrolled exposure .
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11. TROUBLESHOOTING
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.
11.1. TRANSMITTER STATUS LIGHT INDICATORS & WARNINGS
Type Display Type Indication
1
2
3
4
5
6
7
8
9
Slow green blink
(Normal Operation)
Transmitter on and in standby.
Blinking orange
1 red blink followed by a
2-second pause
Button has been pressed and the unit is transmitting.
The speed at which the orange LED blinks is directly related to how far down the button is pressed.
Voltage goes below 1.9V during operation - change batteries immediately.
2 red blinks followed by a
2-second pause
A push button is active while turning on the transmitter.
The button that is active will be designated by the (A, B,
25, 100) LEDs. See Push Button Error Table below.
3 red blinks followed by a
2-second pause
I-CHIP error.
4 red blinks followed by a
2-second pause
Transmitting error, system cannot lock on to the designated channel.
Constant green for up to 2 seconds
Transmitter power on with no faults detected (prior to initiating the START function).
Solid Red
Solid Red
Stop command initiated with receiver
ESTOP deactivated.
Voltage goes below 1.9V at initial power on - transmitter power shuts off.
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11.2. TRANSMITTER PUSH BUTTON ERROR TABLE
A B 25 100 Push Button
OFF OFF OFF ON 1
OFF OFF ON OFF
OFF OFF ON ON
OFF ON OFF OFF
2
3
4
OFF ON OFF ON
OFF ON ON OFF
OFF ON ON ON
ON OFF OFF OFF
ON OFF OFF ON
ON OFF ON OFF
ON OFF ON ON
ON ON OFF OFF
5
6
7
8
9
10
11
12
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11.3. TROUBLESHOOTING TABLE
Problems Possible Reasons Suggestions
No response when transmitter push button is pressed
(Improper startup & settings)
Transmitter low battery power Check the transmitter battery level.
Emergency stop button activated prior to startup
Improper startup procedure
Incorrect system RF channel
Incorrect Receiver Access Code
System out of range
Prior to turning on the transmitter power switch make sure that the red emergency stop button is elevated.
Redo the startup procedure by holding the power key at “START” position for up to 2.0 seconds and then release.
Make sure that the transmitter handset and the receiver unit both have the same channel.
Make sure that the transmitter handset and receiver unit both have the same Receiver
Access Code.
Make sure that the startup procedure is initiated within 100 meters (300 feet) from the receiver location.
Supplied voltage is out of the acceptable range
Ensure the voltage is 120VAC nominal
Receiver will not turn on,
+5VDC CPU/RELAY
LEDs on Power Supply
Module do not light up
Internal fuse has blown on power supply module
Internal Power supply on PCB has a problem
Receiver will not respond to the transmitter
Contact the factory for repair
Contact the factory for repair
WDG/Online LED on CPU/RF module is blinking 2 times
(communication loss with transmitter), and RF MSG LED does not blink.
WDG/Online LED on CPU/RF module is blinking 1 time
(normal operating WDG), RF
MSG LED does not blink and
RF Signal strength LEDs are indicating a signal strength.
WDG/Online LED on CPU/RF module is blinking 1 time
(normal operating WDG), RF
MSG LED does not blink and
RF Signal strength LEDs are indicating an erratic signal.
WDG/Online LED on CPU/RF module is blinking 3 times, read/write error with relay modules
The antenna on the receiver is missing, damaged, or improperly installed.
Make sure the receiver and transmitter unit are both within range. Also verify that the transmitter is still on.
Make sure the receiver and transmitter unit have the same access code.
Make sure the receiver and transmitter are both set to the same channel.
Make sure that the modules are securely put together; if the problem persists, contact factory for repair.
Inspect the antenna on the receiver for damage and try to place the antenna in a location that is visible when operating the equipment at all times.
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Problems Possible Reasons Suggestions
Receiver responds to the transmitter inconsistently
The transmitter is going in and out of range (transmitter and receiver are on the edge of the transmission range)
The antenna and/or cable on the receiver is damaged, or improperly installed.
The transmitter powered down due to inactivity.
Move the transmitter and the receiver closer together
Relocate the receiver antenna to where it is in more line of sight with the transmitter
Inspect the antenna on the receiver for damage and try to place the antenna in a location that is visible when operating the equipment at all times.
Extend the inactivity timeout setting for the transmitter.
The transmitter powered down due to low batteries
Replace the transmitter's batteries.
The MLC (Master) Relay turns off during normal operation
The RF/Message LED stops blinking for more than 3 seconds, followed by the MLC
Relay turning off.
The RF/Message LED stopped and the MLC Relay turned off together within 1 sec, possibly when engaging or disengaging another relay that is driving a contactor.
The serial data timeout error
LED (LED #5) on the serial communication card is lit.
Drive serial communication is inactive or was inactive for more than 1 sec. MLC Relay turned off together when LED is lit.
Radio interference; change the system's channel setting.
CPU module is resetting. Install snubbers across the coils of all contactors to reduce transient voltages. Ensure that the power module has a stable power source.
Error is reset when transmitter issues a start command. Inspect serial communication wiring to ensure there are no breaks, poor connections or damage to the wiring.
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11.4. ASSEMBLY AND REPLACEMENT PARTS
Description
433MHz Part 15, version 2 RF/CPU Module
120VAC Power Supply Module
12VDC @ 1.5A Power Supply Module
9-36VDC Power Supply Module
Relay Module (8 Mechanical relay outputs)
Analog I/O Module (4 0 to +/-10VDC Outputs and 4 0 to +10VDC Inputs)
400MHz Antenna Kit (20’ Cable, Antenna and Bracket)
400MHz Antenna Kit (20’ Cable, 10’ Cable, Antenna & Bracket)
400MHz Antenna Kit (40’ Cable, Antenna and Bracket)
400MHz Antenna Kit (40’ Cable, 10’ Cable, Antenna & Bracket)
NEMA 4 Enclosure, Steel (16”x14”x6”) for Flex M RX, mounted
Module Replacement Plugs
Arc Suppressor/Snubbers
Part Number
25-02-074-816E
25-02-074-804E
25-02-074-810E
25-02-074-820E
25-02-074-805E
25-02-074-806E
178-01377-0530
178-01377-2530
178-01377-0520
178-01377-2520
20-101-0031E
01-300-0031E
20-680-0000E
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12. NOTES
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Key features
- 32 user-programmable channels
- Over one million unique ID codes
- Advanced controls
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- Low power consumption
- Ultra-durable nylon and fiberglass composite enclosures
- Full compliance
- System Versatility