Flex Pro Transmitter
Radio Control Equipment
Instruction Manual
198-50003-R3
July 2011
© Copyright 2011 Magnetek Material Handling
Service Information
Your New Radio System
Thank you for your purchase of Magnetek’s Enrange™ Flex Pro radio remote control system. Without a doubt, our Flex Pro 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:
Magnetek, Inc.
#5 Four Coins Drive
Canonsburg, PA 15317
Telephone:
1.866.MAG.SERV
(1.866.624.7378)
Website: www.magnetekmh.com
E-mail: [email protected]
Fax Numbers:
Main:
Sales:
1.800.298.3503
1.262.783.3510
Service: 1.262.783.3508
Canada Service Information:
4090B Sladeview Crescent
Mississauga, Ontario
L5L 5Y5 Canada
Telephone: 1.800.792.7253
Fax: 1.905.828.5707
1.416.424.7617 (24/7 Service pager)
Table of Contents
Page
Introduction
3
Safety
4
3. General Transmitter Information
A. External Illustration (Pro 12 Configuration)
B. Internal Illustration (Pro 12 Configuration)
10
11
Adjustable Control 12
4. Dip-Switch Settings
System
B. Inactivity Time-Out
5. Operating Procedure
15
Changing
C. Light
D. Push Button Error Table
Tips
18
19
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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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1. Introduction
The Flex radio remote control systems are designed for control of industrial equipment and mobile machinery such as overhead traveling cranes, construction equipment, forestry equipment, mining equipment, rail equipment, drilling & trenching equipment, agriculture equipment, 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 16-bit 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, European Directives
(Safety, EMC, R&TTE, and Machinery), and Industry Canada Specifications (IC).
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2. 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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2.1: 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.
2.2: 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.
2.3: 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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2.4: 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
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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.
2.5: TRANSMITTER UNIT
Transmitter switches should never be mechanically blocked ON or OFF. When not in use, the operator should turn the transmitter OFF. A secure storage space should be provided for the transmitter unit, and the transmitter unit should always be placed 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.
2.6: 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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2.7: 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.
2.8: 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 Telemotive 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).
2.9: BATTERY CHARGING
For those transmitters equipped with battery chargers, please familiarize all users with the instructions of the charger before attempting to use.
Do not attempt to charge non-rechargeable battery packs.
Avoid charging partially discharged rechargeable batteries to help prolong battery cycle life.
Avoid charging 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 Telemotive 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.
2.10: BATTERY DISPOSAL
Before disposing of batteries consult local and governmental regulatory requirements for proper disposal procedure.
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2.11: 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 page 18).
2. Check the Status LED on the transmitter for any signs of irregularities (refer to page 18).
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.
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3. General Transmitter Information
A. External Illustration (Pro 12 Configuration)
(Fig. 01)
1. Push Button #1
2. Push Button #2
Push Button #6 E. Emergency Stop Button
3. Push Button #3
6.
S. Removable Power Key Switch 7.
8.
9.
Push Button #7
Push Button #8
Push Button #9
10. Push Button #10
4. Push Button #4 11. Push Button #11
5. Push Button #5 12. Push Button #12
NOTE: Push Buttons #9-#12 are not present on the Flex Pro 8 Module
(Fig. 02)
SC. Strap Ring
SN. System Information
RN. System Channel
MN. Crane Number
FC. FCC Information
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B. Internal Illustration (Pro 12 Configuration)
(Fig. 03) (Fig. 04)
1. 6.
Antenna
I-CHIP
Module
Dip-Switch
8.
5.
Function LED Displays
NOTE: Flex Pro 8 Module will differ slightly
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C. 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). It is possible to model the stepless buttons as an On/Off momentary switch, On/Off latched switch, 2 Speed button, or a 3 Speed button. This modeling is done on the receiver end of the system. Please consult the factory for more information.
D. Adjustable Speed Control
The proportional buttons normally operate on a scale from 0-100%, but can also be scaled down to operate linearly from 0-75%, 0-50%, or 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 + Speed control setting
PB1 Decrement Speed Control
PB2 Increment Speed Control
(Fig. 05) (Fig. 06)
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4. Dip-Switch Settings
A. System Channel Settings
Set the transmitter channel by adjusting the channel dip-switch located on the backside of the transmitter encoder board (refer to Fig. 07 below). Only the first five (5) positions of the dip-switch are used for channel programming (refer to Fig. 08 below). The system channels table (on page 14) 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.
(Fig. 07) (Fig. 08)
Top slot → “1”
Bottom slot → “0”
The above dip-switch setting “1 0 0 1 0” corresponds to “channel 19” in the system channels table (on page 14).
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01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
Channel 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
System Channel Table
Dip-switch
Setting
Channel Frequency
00000
00001
17
18
433.800MHZ
433.850MHZ
00010
00011
00100
00101
00110
00111
01000
01001
01010
01011
01100
01101
01110
19
20
21
22
23
24
25
26
27
28
29
30
31
433.750MHZ 01111 32
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
Dip-switch
Setting
10000
10001
10010
10011
10100
10101
10110
10111
11000
11001
11010
11011
11100
11101
11110
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B. 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
5 minutes
10 minutes
15 minutes
Never shut off
Dipswitch
Setting
01
10
11
00
(Fig.09)
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5. Operating Procedure
A. General
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.
(Fig. 10)
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.
(Fig. 11) (Fig. 12)
3. After turning on the transmitter power, check the Status LED on the transmitter handset for any sign of system irregularities (refer to “Status Light Indicators & Warnings” on page 18).
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.
(Fig. 13)
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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 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 ESTOP 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.
B. Changing Transmitter Batteries
Change the transmitter batteries by unscrewing the battery cover located on the backside of the transmitter (refer to Fig. 14 and Fig. 15 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
(Fig. 14)
↓
(Fig. 15)
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C. Status Light Indicators & Warnings
Indication
1
2
3
4
5
6
7
Slow green blink
(Normal Operation)
3 red blinks followed by a
2-second pause
Transmitter on and in standby.
Blinking orange
1 red blink followed by a 2second pause
2 red blinks 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.
A push button is active while turning on the transmitter.
The button that is active will be designated by the (25,
50, 75, 100) LEDs. See Push Button Error Table below.
I-CHIP error.
4 red blinks followed by a
2-second pause
Constant green for up to 2 seconds
Transmitting error, system can not lock on to the designated channel.
Transmitter power on with no faults detected (prior to initiating the START function).
8
Solid Red
Stop command initiated with receiver
ESTOP deactivated.
9
Solid Red
Voltage goes below 1.9V at initial power on - transmitter power shuts off.
D. Push Button Error Table
OFF OFF OFF ON
OFF OFF ON OFF
OFF OFF ON ON
OFF ON OFF OFF
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
1
2
3
4
5
6
7
8
9
10
11
12
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E. Trouble Shooting Tips
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
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.
Incorrect Receiver Access Code
System out of range
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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