Magnetek Flex EM/EX HazLoc Transmitter Owner's Manual
Magnetek Flex EM/EX HazLoc Transmitter is a high-performance radio remote control system designed for use in hazardous locations. With its durable construction and advanced safety features, it's ideal for applications where reliability and safety are paramount. The transmitter features a 12-button configuration, allowing for precise control of various functions. It also includes a backlit display for clear visibility in low-light conditions and an adjustable inactivity time-out timer to prevent unintended operation.
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Flex EM/EX HazLoc Transmitter
Engineered
Remote Equipment Control
Instruction Manual
Part Number: 191-90001-M0090F R01
March 2019
©Copyright 2019 Magnetek Material Handling
Page Intentionally Left Blank
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Table of Contents
1 Radio Controlled Safety .....................................................................................................................7
2 Critical Installation Considerations ..................................................................................................8
2.1
2.2
General.........................................................................................................................................8
Persons Authorized to Operate Radio Controlled Cranes............................................................8
2.3
2.4
2.5
2.6
Safety Information and Recommended Training for Radio Controlled Equipment Operators......9
Transmitter Unit..........................................................................................................................10
Pre-Operation Test.....................................................................................................................10
Batteries .....................................................................................................................................10
2.7
2.8
Battery Handling.........................................................................................................................11
Battery Disposal .........................................................................................................................11
3 General Transmitter Information.....................................................................................................12
3.1
External Illustration (12-Button Configuration) ...........................................................................12
3.2
3.3
Internal Illustration (12-Button Configuration).............................................................................13
Types of Buttons ........................................................................................................................13
4 Dip-Switch Settings ..........................................................................................................................14
4.1
System Channel Settings ...........................................................................................................14
4.2
Inactivity Time-Out Timer ...........................................................................................................14
5 Operating Procedure ........................................................................................................................15
5.1
5.2
General Operating Procedure ....................................................................................................15
Changing Transmitter Batteries..................................................................................................16
5.3
5.4
Status Lights Indicators and Warnings.......................................................................................17
Push Button Error Table.............................................................................................................18
6 Channel Configuration Settings......................................................................................................19
6.1
FCC Statements.........................................................................................................................19
6.2
Channel Table ............................................................................................................................20
7 Troubleshooting ...............................................................................................................................21
7.1
Troubleshooting Table................................................................................................................21
8 Declaration of Conformity................................................................................................................22
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SERVICE INFORMATION
Your New Radio Remote Control System
Thank you for your purchase of Magnetek’s Flex EM/EX Radio Remote Equipment Control System.
Magnetek has set a whole new standard in radio-remote performance, dependability, and value with this unique line of handheld transmitters.
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:
Fax Numbers:
800-288-8178 www.magnetek.com
Main:
Sales:
Service:
800-298-3503
262-783-3510
262-783-3508
Canada Service Information:
161 Orenda Road
Unit 1
Brampton, Ontario
L6W 1W3 Canada
Phone: 800-792-7253
Fax: 905-828-5707
416-424-7617 (24/7 Service pager)
EU Market Contact:
Brian Preston
Magnetek (UK) Ltd.
Unit 3 Bedford Business Centre
Mile Road
Bedford, MK42 9TW UK
Phone: +44-1234-349191
© 2019 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.
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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.
WARRANTY INFORMATION
FOR INFORMATION ON MAGNETEK’S PRODUCT WARRANTIES BY PRODUCT TYPE, PLEASE
VISIT WWW.MAGNETEK.COM.
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1 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
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices.
NOTE:
A NOTE statement is used to notify people of installation, operation, programming, or maintenance information that is important, but not hazard-related.
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 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.
2.1 General
Radio controlled material handling equipment operates in several directions. Cranes, hoists, lifting devices and other material handling equipment can be large and can operate at high speeds. The equipment is often 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, prevent damage to equipment, or even save a life.
2.2 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.
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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 that may cause them to lose control of the equipment, is taking any medication that may cause loss of equipment control, or is under the influence of alcohol or drugs.
2.3 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
• 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
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• 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.
2.4 Transmitter Unit
Transmitter switches should never be mechanically blocked on or off. When not in use, the operator should turn off the transmitter. 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.
2.5 Pre-Operation Test
At the start of each work shift, or when a new operator takes control of the crane, operators should do, as a minimum, the following steps before making lifts with any crane or hoist:
Test all warning devices.
Test all direction and speed controls.
Test the transmitter emergency stop.
2.6 Batteries
Refer to the Enrange Flex EM/EX/Pro Transmitter ATEX/IECEx Information sheet (198-80210-0010) for a list of batteries approved for use with the Flex HazLoc system.
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.
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2.7 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 (for example, not in direct sunlight or close to a heating source) during charging, operation and storage.
2.8 Battery Disposal
Before disposing of batteries, consult local and governmental regulatory requirements for proper disposal procedure.
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3 General Transmitter Information
3.1 External Illustration (12-Button Configuration)
7.
8.
5.
6.
3.
4.
1.
2.
9.
10.
Emergency STOP Button
Removable Power Key
Pushbutton #1
Pushbutton #3
Pushbutton #5
Pushbutton #7
Pushbutton #9
Pushbutton #11
Pushbutton #2
Pushbutton #4
Fig. 1
15.
16.
17.
18.
11.
12.
13.
14.
19.
20.
Pushbutton #6
Pushbutton #8
Pushbutton #10
Pushbutton #12
Strap Ring
System Information
System Channel
Unit Number
Battery Cover
FCC Information
NOTE:
Push Buttons #9 – #12 are not present on the Flex 8EM or 8EX.
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3.2 Internal Illustration (12-Button Configuration)
Fig. 2
3.
4.
1.
2.
5.
Encoder Board
Aerial Antenna
Transmitting Module
Status LED Display
Function LED Displays
NOTE:
The Flex 8EM or 8EX will differ slightly.
8.
9.
6.
7.
I-CHIP
Dip-Switch Bank 1
Dip-Switch Bank 2
Battery Contact Mechanism
3.3 Types of Buttons
Both the Flex EM and EX are offered in either 8-button or 12-button configurations. The illustrations in this manual show the 12-button configurations. The difference between the Flex EM and Flex EX transmitters is the type of buttons: The Flex EM transmitter has single-step (speed) push buttons while the Flex EX has two-step (speed) buttons. For additional information on how these buttons operate the system, consult the drawings provided with the system.
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4 Dip-Switch Settings
4.1 System Channel Settings
Set the transmitter channel by adjusting the dip-switch bank 2 located on the backside of the transmitter encoder board (refer to Fig. 2). Only the first 5 positions of the dip-switch are used for channel programming (refer to Fig. 3). The system channels table (Section 6.2) illustrates which dip-switch setting corresponds to which channel. Once the transmitter channel has been altered, the receiver must be set up to recognize the transmitter on its new channel.
Top slot → “1
Bottom slot → “0
Fig. 3
The above dip-switch setting
“1 0 0 1 0”
corresponds to channel 19 in the system channels table (Section
6.2).
4.2 Inactivity Time-Out Timer
Bits 6 and 7 on dip-switch bank 2 (refer to Fig. 4) allow the user to define a time after which, if no buttons on the transmitter are pressed, the Flex transmitter will send an OFF command to the receiver and power down. To restart the unit, the user must turn the ON/OFF/START switch to the OFF position and then back to ON again to resume operation.
Time Out
5 minutes
10 minutes
15 minutes
Never shut off
Dip-switch Setting
01
10
11
00
Fig. 4
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5 Operating Procedure
5.1 General Operating Procedure
1. Reset the red emergency stop button located on the top left hand side of the transmitter handset by turning it either clockwise or counterclockwise. The red button will pop up.
Fig. 5
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 turn it clockwise to the
ON position.
Fig. 6
Fig. 7
3. After turning on the transmitter power, check the Status LED on the transmitter handset for any sign of system irregularities (refer to Section 5.3). If the system is normal, the Status
LED will light up green for 2 seconds and then slowly flash green.
4. If there are no signs of any system irregularities, then turn 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.
Fig. 8
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5. 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 flash 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, turn the red button either clockwise or counterclockwise 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 be power cycled before being turned on again.
8. Turn off the transmitter power by turning the power key counterclockwise to the OFF position. The Status LED displays a solid red for 4 seconds. This will disconnect the transmitter power and the receiver E-Stop altogether. Turn it further counterclockwise to release the key.
5.2 Changing Transmitter Batteries
Refer to the Enrange Flex EM/EX/Pro Transmitter ATEX/IECEx Information sheet (198-80210-0010) for a list of batteries approved for use with the Flex HazLoc system.
Change the transmitter batteries by unscrewing the battery cover located on the backside of the transmitter (refer to Fig. 9 and Fig. 10). 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.
Fig. 9
↓
2
1
Fig. 10
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5.3 Status Lights Indicators and Warnings
Type
1
2
3
4
7
8
9
5
6
Display Type
Slow green flash
(Normal operation)
Flashing orange
1 red flash followed by a
2-second pause
2 red flashes followed by a
2-second pause
3 red flashes followed by a
2-second pause
4 red flashes followed by a
2-second pause
Solid green for up to 2 seconds
Solid red
Solid red
Indication
Transmitter on and in standby.
Button has been pressed and the unit is transmitting. The speed at which the orange LED flashes is directly related to how far down the button is pressed.
Voltage goes below 1.9V during operation – change batteries immediately.
A push button is active while turning on the transmitter. The button that is active will be designated by the (D, C, B, A)
LEDs.
See Section 5.4 on page 18
.
I-CHIP error.
Transmitting error – system cannot lock on to the designated channel.
Transmitter power on with no faults detected (prior to initiating the START function).
Stop command initiated with receiver E-Stop deactivated.
Voltage goes below 1.9V at initial power-on – transmitter power shuts off.
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5.4 Push Button Error Table
D
OFF
OFF
OFF
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
C B
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF OFF
OFF ON
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
A
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Push Button
7
8
5
6
3
4
1
2
9
10
11
12
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6 Channel Configuration Settings
6.1 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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6.2 Channel Table
13
14
15
16
09
10
11
12
05
06
07
08
01
02
03
04
Channel Frequency
433.000 MHZ
433.050 MHZ
433.100 MHZ
433.150 MHZ
433.200 MHZ
433.250 MHZ
433.300 MHZ
433.350 MHZ
433.400 MHZ
433.450 MHZ
433.500 MHZ
433.550 MHZ
433.600 MHZ
433.650 MHZ
433.700 MHZ
433.750 MHZ
Dip-switch
Setting
01000
01001
01010
01011
01100
01101
01110
01111
00000
00001
00010
00011
00100
00101
00110
00111
Channel
29
30
31
32
25
26
27
28
21
22
23
24
17
18
19
20
Frequency
433.800 MHZ
433.850 MHZ
433.900 MHZ
433.950 MHZ
434.000 MHZ
434.050 MHZ
434.100 MHZ
434.150 MHZ
434.200 MHZ
434.250 MHZ
434.300 MHZ
434.350 MHZ
434.400 MHZ
434.450 MHZ
434.500 MHZ
434.550 MHZ
Dip-switch
Setting
11000
11001
11010
11011
11100
11101
11110
11111
10000
10001
10010
10011
10100
10101
10110
10111
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7 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.
7.1 Troubleshooting Table
Problems
No response when transmitter push button is pressed (Improper startup and settings)
Possible Reasons
Transmitter low battery power
Emergency stop button activated prior to startup
Improper startup procedure
Incorrect system
RF channel
Incorrect Receiver
Access Code
System out of range
Suggestions
Check the transmitter battery level.
Prior to turning on the transmitter power switch, make sure that the red emergency stop button is elevated.
Repeat 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.
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8 Declaration of Conformity
EU Declaration of Conformity Certificate
For the following equipment:
Product
Multiple Listee Model No.
Product Receiver Models
Manufacturer’s Name
: Flex Series Radio Remote Control – Hazloc Versions
: Flex 4ES/EX/EM, Flex 6EX, Flex 8ES/EX/EM, Flex 12ES/EX/EM, Flex 8/12 PRO
: CAN-2, MHR, WIC-2402, Flex 4 RX, Flex 6 RX, Flex 8R X, Flex 12 RX
: Magnetek, Inc.
W13650 Drive
_________
Menomonee Falls, WI 53051 USA
The undersigned hereby declares on behalf of Magnetek, that the above-referenced products, to which this declaration relates, is in conformity with the provisions of
CE Mark Directive (93/68/EEC), ATEX II Directive (2014/34/EU), Machinery Safety Directive (MD, 2006/42/EC), Radio Equipment Directive (RED, 2014/53/EU), EMC
Directive (2014/30/EU), and the ROHS2 Directive (2011/65/EU).
The standards relevant for the evaluation of the product referenced above conformity to the directive requirements are as follows:
EN 301 489-1 v1.9.2:2011
EN 301 489-3 v1.4.1:2002-04
EN 300 220-1 v2.3.1:2010
EN 300 220-2 v2.3.2:2010
EN 60204-32:1998
EN 60950-1:2006+A11:2009+A1:2010+A12:2011
EN 60529:1992
EN ISO 13849-1:2008
EN 13557:2003+A2:2008
EN 60079-0:2012
EN 60079-11:2012
ATEX specific information:
Product is in conformity with the EC type examination certificate:
DEMKO 16 ATEX 1601X
For Equipment Group and Category:
II 3 G
Type of Protection:
ic
Group:
IIC
Temperature
Issued by the notified body:
DK-2730 Herlev
Kenn-Nr. / ident. No. 0539
The product has been manufactured, finally inspected and tested under a quality system, which has been approved by the notified body:
2500 West Dundee Road
Northbrook, IL 60062
The European contact for Magnetek is: Brian Preston
Magnetek
Per Annex II.B of the Machinery Directive (2006/42/EC):
Mile Road
Bedford
MK42 9TW
United Kingdom
The machinery, product, assembly or sub-assembly covered by this Declaration of Conformity must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the applicable Directive(s). This statement is only necessary where the product is to be incorporated into a machine or system (e.g. a safety component).
Signature of Authorized Person:
Travis Tedesco
Engineering Development Manager
Columbus McKinnon Corporation
Bridgeville, PA USA
Date of Issuance: 31 January 2019 Peter Stipan
Director of Development
Columbus McKinnon Corporation
Menomonee Falls, WI USA
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