Magnetek Flex 8EX A/B Instruction manual
Below you will find brief information for Flex 12EX System. This manual details the features, safety information, and operating procedures for the Flex 12EX radio remote control system. It covers topics like system setup, function settings, safety guidelines, and troubleshooting to ensure safe and effective use of the equipment.
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Flex 12EX System
Radio Control Equipment
Instruction Manual
0-TC-FLEX12E R4
December 2013
© Copyright 2013 Magnetek Material Handling
Service Information
Your New Radio System
Thank you for your purchase of Magnetek’s Enrange™ Flex EX radio remote control system. Without a doubt, our Flex EX system is the ultimate solution for providing precise, undeterred, and safe control of your material.
If your product ever needs modification or service, please contact one of our representatives at the following locations:
U.S. Service Information
For questions regarding service or technical information contact:
+1.866.MAG.SERV
+1.866.624.7378
World Headquarters:
Magnetek, Inc.
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
Telephone: +1.800.288.8178
Website: www.magnetek.com
e-mail:
Fax Numbers:
Main:
+1.800.298.3503
Sales:
Service:
+1.262.783.3510
+1.262.783.3508
Magnetek, Inc. has additional satellite locations for Canada and the United States. For more information, please visit http://www.magnetek.com.
©2013 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 12EX System Instruction Manual
December 2013
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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.magnetek.com.
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Table of Contents
1. INTRODUCTION ............................................................................................................................................. 6
2. RADIO CONTROLLED SAFETY ..................................................................................................................... 7
2.1 CRITICAL INSTALLATION CONSIDERATIONS ....................................................................................... 8
2.2 GENERAL ................................................................................................................................................. 8
2.3 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED CRANES .......................................... 8
2.4 SAFETY INFORMATION AND RECOMMENDED TRAINING FOR RADIO CONTROLLED
EQUIPMENT OPERATORS ............................................................................................................................ 9
2.5 TRANSMITTER UNIT ............................................................................................................................. 10
2.6 PRE-OPERATION TEST ......................................................................................................................... 10
2.7 BATTERIES ............................................................................................................................................. 11
2.8 BATTERY HANDLING............................................................................................................................. 11
2.9 BATTERY CHARGING ............................................................................................................................ 11
2.10 BATTERY DISPOSAL ........................................................................................................................... 11
2.11 SPECIFIC SYSTEM WARNINGS ......................................................................................................... 12
3. GENERAL SYSTEM INFORMATION ............................................................................................................ 13
3.1 TRANSMITTER HANDSET ..................................................................................................................... 13
3.1.1 External Illustration (Standard Push Button Configuration) ............................................................. 13
3.1.2 Internal Illustration ............................................................................................................................ 14
3.2 RECEIVER UNIT ..................................................................................................................................... 15
3.2.1 External Illustration .......................................................................................................................... 15
3.2.2 Internal Illustration ............................................................................................................................ 16
4. FUNCTION SETTINGS ................................................................................................................................. 17
4.1 TRANSMITTER HANDSET ..................................................................................................................... 17
4.1.1 System Channel Settings ................................................................................................................ 17
4.1.2 Push Button Functions with LED Display Settings .......................................................................... 18
4.1.2.1 Standard Push Button (Transmitter Toggle) ............................................................................. 18
4.1.2.2 Standard Push Button Configuration (A/B Selector) ................................................................ 19
4.1.2.3 Inline Push Button Configuration (Transmitter Toggle) ............................................................. 22
4.1.2.4 Inline Push Button Configuration (A/B Selector) ...................................................................... 23
4.1.3 Channel Change via Push Buttons .................................................................................................. 26
4.1.4 Optional 4-Digit Security Code ........................................................................................................ 27
4.1.5 I-CHIP .............................................................................................................................................. 28
4.2 RECEIVER UNIT ..................................................................................................................................... 29
4.2.1 System Channel Settings ................................................................................................................ 29
4.2.2 Output Relay Configurations ............................................................................................................ 30
4.2.2.1 Output Relay Types .................................................................................................................. 30
4.2.2.2 Output Relay Actions at 2 nd
Speed ........................................................................................... 30
4.2.2.3 ON/OFF Push Button Function ................................................................................................ 31
4.2.2.4 START/AUX Function ............................................................................................................... 32
4.2.2.5 Magnet ON/OFF Push Button Function ................................................................................... 32
4.2.2.6 Brake Function ......................................................................................................................... 32
4.2.2.7 Momentary Contact .................................................................................................................. 32
4.2.2.8 Toggled Contact ........................................................................................................................ 32
4.2.2.9 3 rd
Speed Push Button Function ............................................................................................... 32
4.2.2.10 Auxiliary STOP Push Button Function .................................................................................... 33
4.2.2.11 Pitch & Catch Function ........................................................................................................... 33
4.2.3 Receiver Auto-Scanning Settings .................................................................................................... 33
4.2.4 Dip-Switch Settings .......................................................................................................................... 34
4.2.4.1 Interlocked Functions ............................................................................................................... 34
4.2.4.2 Non-Interlocked Functions........................................................................................................ 35
4.2.5 Jumper Settings ............................................................................................................................... 36
4.2.6 I-CHIP Programming Port ................................................................................................................ 37
4.2.7 Voltage Settings ............................................................................................................................... 37
5. SYSTEM CHANNELS TABLE ....................................................................................................................... 38
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6. RECEIVER INSTALLATION .......................................................................................................................... 39
6.1 OUTPUT RELAY CONTACT DIAGRAM ................................................................................................. 39
6.2 PRE-INSTALLATION PRECAUTIONS ................................................................................................... 40
6.3 STEP-BY-STEP INSTALLATION ............................................................................................................. 40
6.4 SYSTEM TESTING ................................................................................................................................. 41
7. OPERATING PROCEDURE .......................................................................................................................... 42
7.1 TRANSMITTER OPERATION ................................................................................................................. 42
7.1.1 General Operating Procedure .......................................................................................................... 42
7.1.2 A/B Selector Push Button Operating Procedure .............................................................................. 43
7.1.3 3 rd
Speed Push Button Operating Procedure .................................................................................. 43
7.1.4 Pitch & Catch Operating Procedure ................................................................................................. 44
7.1.5 Automatic Channel Scanning Operating Procedure ........................................................................ 44
7.1.6 Changing Transmitter Batteries ....................................................................................................... 44
7.2 STATUS LIGHT INDICATORS & WARNINGS ........................................................................................ 45
7.2.1Transmitter STATUS Light Indication ................................................................................................ 45
7.2.2 Receiver STATUS Light Indication ................................................................................................... 46
7.2.3 Receiver SQ Light Indication ........................................................................................................... 46
7.2.4 Receiver POWER Light Indication ................................................................................................... 46
7.2.5 Receiver COM Light Indication ........................................................................................................ 46
7.3 TROUBLESHOOTING TIPS ................................................................................................................... 47
8. SYSTEM SPECIFICATIONS ......................................................................................................................... 48
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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 receiver unit. Other standard-equipped accessories include 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:
* 62 user-programmable channels – Advanced synthesized RF controls with 62 built-in channels; there are no more fixed channel and fragile quartz crystals to break.
* Automatic channel scanning receiver – No more hassle of climbing up the crane to change receiver channels.
* Over one million unique ID codes (20bit) – Each and every Flex system has its own unique ID codes and serial number; no repeats.
* Advanced controls – The Flex system utilizes advanced microprocessor controls with 32bit CRC and
Hamming Code, which provide ultra-fast, safe, precise, and error-free encoding and decoding.
* Unique I-CHIP design – The I-CHIP functions in a way that is very similar to 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 with gold-plated contacts 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
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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.
2.5 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 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 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 4EX system:
1. Check the Status LED on the transmitter for any signs of low battery power (refer to page 45).
2. Check the Status LED on the transmitter for any signs of irregularities (refer to page 45).
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 SYSTEM INFORMATION
3.1 TRANSMITTER HANDSET
3.1.1 External Illustration (Standard Push Button Configuration)
(Fig. 01) (Fig. 02)
1. Emergency Stop Button 8.
2. Removable Power Key Switch 9.
3. Push Button #2
4. Push Button #4
10.
11.
Push Button #12
Push Button #1
Push Button #3
Push Button #5
15. Strap Ring
16. System Information
17. System Channel
18. Crane Number
5. Push Button #6
6. Push Button #8
12.
13.
Push Button #7
Push Button #9
19.
20.
Battery Cover
FCC Information
Push #10 14. #11
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3.1.2 Internal Illustration
(Fig. 03) (Fig. 04)
Encoder 6.
7.
Module
Function
Display
Channel
9.
5. Function LED Displays
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3.2 RECEIVER UNIT
3.2.1 External Illustration
(Fig. 05)
1.
2. Optional External Antenna (BNC) Jack
3.
4.
5.
LED
SQ LED Display
7. Output Contact Diagram
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3.2.2 Internal Illustration
1.
2.
3.
Transformer
Module
(Fig. 06)
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4. FUNCTION SETTINGS
4.1 TRANSMITTER HANDSET
4.1.1 System Channel Settings
CHANNEL
1 2 3 4 5 6 7 8
(Fig. 07)
Set the transmitter channel by adjusting the channel dip-switch located on the backside of the transmitter encoder board (refer to Fig. 07 above). Only the first six (6) positions are used for channel programming (refer to Fig. 08 below). The system channels table located on page 38 illustrates which dip-switch setting corresponds to which channel. Once the transmitter channel is altered make sure to change the receiver channel as well. The channel on both the transmitter and receiver must be identical in order for the system to work. To change the receiver channel please refer to page 29.
Example:
(Fig. 08)
1 2 3 4 5 6 7 8
Top slot → “1”
Bottom slot → “0”
The above dip-switch setting “1 0 0 1 0 0” corresponds to “channel 36” in the system channels table on page 38.
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4.1.2 Push Button Functions with LED Display Settings
4.1.2.1 Standard Push Button (Transmitter Toggle)
Set transmitter toggle (latching output relay) function by adjusting the 8-position function dip-switch located on the backside of the transmitter encoder board (refer to Fig. 09 below). The LED 1 through LED 4 shown inside the shaded box (see below) illustrates which LED on the transmitter will light up when the designated push button (PB7 ~ PB12) is pressed.
LED 4 LED 3 LED 2 LED 1
(Fig. 09)
FUNCTION
1 2 3 4 5 6 7 8
DIP PB8 PB12
1 00000000 Normal Normal Normal Normal Normal
2 00001001 Normal Normal Normal LED 4 Normal Normal
3 00001010 Normal Normal LED 3 LED 4 Normal Normal
4 00001011 Normal LED 2 LED 3 LED 4 Normal Normal
5 00001100 LED 1 LED 2 LED 3 LED 4 Normal Normal
6 00001101 Normal Normal Normal Normal Normal LED 4
7 00001110 Normal Normal Normal Normal LED 3 LED 4
8 00001111 Normal Normal Normal LED 2 LED 3 LED 4
9 00010000 Normal Normal LED 1 LED 2 LED 3 LED 4
* LED 1…LED 4 → Transmitter toggled with designated LED Display
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4.1.2.2 Standard Push Button Configuration (A/B Selector)
There are four (4) different types of A/B selector sequences available on the Flex system.
Choose the one that is most suitable for your application. selector :
Type-B selector sequence
Type-C selector sequence
Type-D selector sequence
:
:
:
Off → A → B → Off → A → B …
A → B → A+B → A → B → A+B …
Off → A → B → A+B → Off → A → B → A+B …
DIP PB8 PB12
10 00101111 A/1&2 Normal Normal Normal Normal Normal
11 00110000 B/1&2 Normal Normal Normal Normal Normal
12 00110001 C/1&2 Normal Normal Normal Normal Normal
13 00110010 D/1&2 Normal Normal Normal Normal Normal
14 00110011 Normal A/3&4 Normal Normal Normal Normal
15 00110100 Normal B/3&4 Normal Normal Normal Normal
16 00110101 Normal C/3&4 Normal Normal Normal Normal
17 00110110 Normal D/3&4 Normal Normal Normal Normal
18 00110111 A/1&2 A/3&4 Normal Normal Normal Normal
19 00111000 A/1&2 B/3&4 Normal Normal Normal Normal
20 00111001 A/1&2 C/3&4 Normal Normal Normal Normal
21 00111010 A/1&2 D/3&4 Normal Normal Normal Normal
22 00111011 B/1&2 B/3&4 Normal Normal Normal Normal
23 00111100 B/1&2 C/3&4 Normal Normal Normal Normal
24 00111101 B/1&2 D/3&4 Normal Normal Normal Normal
25 00111110 C/1&2 C/3&4 Normal Normal Normal Normal
26 00111111 C/1&2 D/3&4 Normal Normal Normal Normal
27 01000000 D/1&2 D/3&4 Normal Normal Normal Normal
*
*
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DIP PB8 PB12
28 01000001 Normal Normal A/1&2 Normal Normal Normal
29 01000010 Normal Normal B/1&2 Normal Normal Normal
30 01000011 Normal Normal C/1&2 Normal Normal Normal
31 01000100 Normal Normal D/1&2 Normal Normal Normal
32 01000101 Normal Normal Normal A/3&4 Normal Normal
33 01000110 Normal Normal Normal B/3&4 Normal Normal
34 01000111 Normal Normal Normal C/3&4 Normal Normal
35 01001000 Normal Normal Normal D/3&4 Normal Normal
36 01001001 Normal Normal A/1&2 A/3&4 Normal Normal
37 01001010 Normal Normal A/1&2 B/3&4 Normal Normal
38 01001011 Normal Normal A/1&2 C/3&4 Normal Normal
39 01001100 Normal Normal A/1&2 D/3&4 Normal Normal
40 01001101 Normal Normal B/1&2 B/3&4 Normal Normal
41 01001110 Normal Normal B/1&2 C/3&4 Normal Normal
42 01001111 Normal Normal B/1&2 D/3&4 Normal Normal
43 01010000 Normal Normal C/1&2 C/3&4 Normal Normal
44 01010001 Normal Normal C/1&2 D/3&4 Normal Normal
45 01010010 Normal Normal D/1&2 D/3&4 Normal Normal
*
*
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DIP PB8 PB12
46 01010011 Normal Normal Normal Normal A/1&2 Normal
47 01010100 Normal Normal Normal Normal B/1&2 Normal
48 01010101 Normal Normal Normal Normal C/1&2 Normal
49 01010110 Normal Normal Normal Normal D/1&2 Normal
50 01010111 Normal Normal Normal Normal Normal A/3&4
51 01011000 Normal Normal Normal Normal Normal B/3&4
52 01011001 Normal Normal Normal Normal Normal C/3&4
53 01011010 Normal Normal Normal Normal Normal D/3&4
54 01011011 Normal Normal Normal Normal A/1&2 A/3&4
55 01011100 Normal Normal Normal Normal A/1&2 B/3&4
56 01011101 Normal Normal Normal Normal A/1&2 C/3&4
57 01011110 Normal Normal Normal Normal A/1&2 D/3&4
58 01011111 Normal Normal Normal Normal B/1&2 B/3&4
59 01100000 Normal Normal Normal Normal B/1&2 C/3&4
60 01100001 Normal Normal Normal Normal B/1&2 D/3&4
61 01100010 Normal Normal Normal Normal C/1&2 C/3&4
62 01100011 Normal Normal Normal Normal C/1&2 D/3&4
63 01100100 Normal Normal Normal Normal D/1&2 D/3&4
*
*
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4.1.2.3 Inline Push Button Configuration (Transmitter Toggle)
The push button arrangement for inline push button setup starts from top to bottom and then from right column to left column (refer to Fig. 10 below). To set inline push button configuration please refer to JP4 and JP5 jumpers setting on page 36. With inline push buttons configuration, PB1 & PB2 still corresponds to output relay K1 - K4; PB3 & PB4 corresponds to relay K5 - K8; etc…
(Fig. 10)
DIP PB8 PB12
64 00000000 Normal Normal Normal Normal Normal
65 00000101 Normal Normal Normal LED 4 Normal Normal
66 00010100 Normal Normal LED 3 LED 4 Normal Normal
67 00010101 Normal LED 2 LED 3 LED 4 Normal Normal
68 00010110 LED 1 LED 2 LED 3 LED 4 Normal Normal
69 00001001 Normal Normal Normal Normal LED 4 Normal
70 00010111 Normal Normal Normal LED 3 LED 4 Normal
71 00011000 Normal Normal LED 2 LED 3 LED 4 Normal
72 00011001 Normal LED 1 LED 2 LED 3 LED 4 Normal
73 00001101 Normal Normal Normal Normal Normal LED 4
74 00011010 Normal Normal Normal Normal LED 3 LED 4
75 00011011 Normal Normal Normal LED 2 LED 3 LED 4
76 00011100 Normal Normal LED 1 LED 2 LED 3 LED 4
* LED 1…LED 4 → Transmitter toggled with designated LED Display
Flex 12EX System Instruction Manual
December 2013
Page 22 of 48
4.1.2.4 Inline Push Button Configuration (A/B Selector)
There are four (4) different types of A/B selector sequences available on the Flex system.
Choose the one that is most suitable for your application. selector :
Type-B selector sequence
Type-C selector sequence
Type-D selector sequence
:
:
:
Off → A → B → Off → A → B …
A → B → A+B → A → B → A+B …
Off → A → B → A+B → Off → A → B → A+B …
DIP PB9 PB10 PB11 PB12
77 01110011 A/1&2 Normal Normal Normal
78 01110100 B/1&2 Normal Normal Normal
79 01110101 C/1&2 Normal Normal Normal
80 01110110 D/1&2 Normal Normal Normal
81 00110011 Normal A/3&4 Normal Normal
82 00110100 Normal B/3&4 Normal Normal
83 00110101 Normal C/3&4 Normal Normal
84 00110110 Normal D/3&4 Normal Normal
85 01110111 A/1&2 A/3&4 Normal Normal
86 01111000 A/1&2
87 01111001 A/1&2
B/3&4 Normal Normal
C/3&4 Normal Normal
88 01111010 A/1&2
89 01111011 B/1&2
90 01111100 B/1&2
91 01111101 B/1&2
92 01111110 C/1&2
93 01111111 C/1&2
94 10000000 D/1&2
D/3&4 Normal Normal
B/3&4 Normal Normal
C/3&4 Normal Normal
D/3&4 Normal Normal
C/3&4 Normal Normal
D/3&4 Normal Normal
D/3&4 Normal Normal
Flex 12EX System Instruction Manual
December 2013
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95 10000001 Normal A/1&2 Normal Normal
96 10000010 Normal B/1&2 Normal Normal
97 10000011 Normal C/1&2 Normal Normal
98 10000100 Normal D/1&2 Normal Normal
99 01000101 Normal Normal A/3&4 Normal
100 01000110 Normal Normal B/3&4 Normal
101 01000111 Normal Normal C/3&4 Normal
102 01001000 Normal Normal D/3&4 Normal
103 10000101 Normal A/1&2 A/3&4 Normal
104 10000110 Normal A/1&2
105 10000111 Normal A/1&2
106 10001000 Normal A/1&2
107 10001001 Normal B/1&2
108 10001010 Normal B/1&2
B/3&4 Normal
C/3&4 Normal
D/3&4 Normal
B/3&4 Normal
C/3&4 Normal
109 10001011 Normal B/1&2
110 10001100 Normal C/1&2
111 10001101 Normal C/1&2
112 10001110 Normal D/1&2
*
*
D/3&4 Normal
C/3&4 Normal
D/3&4 Normal
D/3&4 Normal
Flex 12EX System Instruction Manual
December 2013
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113 10001111 Normal Normal A/1&2 Normal
114 10010000 Normal Normal B/1&2 Normal
115 10010001 Normal Normal C/1&2 Normal
116 10010010 Normal Normal D/1&2 Normal
117 01010111 Normal Normal Normal A/3&4
118 01011000 Normal Normal Normal B/3&4
119 01011001 Normal Normal Normal C/3&4
120 01011010 Normal Normal Normal D/3&4
121 10010011 Normal Normal A/1&2 A/3&4
122 10010100 Normal Normal A/1&2
123 10010101 Normal Normal A/1&2
124 10010110 Normal Normal A/1&2
125 10010111 Normal Normal B/1&2
126 10011000 Normal Normal B/1&2
B/3&4
C/3&4
D/3&4
B/3&4
C/3&4
127 10011001 Normal Normal B/1&2
128 10011010 Normal Normal C/1&2
129 10011011 Normal Normal C/1&2
130 10011100 Normal Normal D/1&2
*
*
D/3&4
C/3&4
D/3&4
D/3&4
Flex 12EX System Instruction Manual
December 2013
Page 25 of 48
4.1.3 Channel Change via Push Buttons
Other than CHANNEL dip-switch on the encoder board, the transmitter channel can also be changed directly on the push buttons. Please refer to the instruction below on how to change the transmitter channel via push buttons. a. Press and hold PB1, PB2 and PB3 and rotate the power key to START position at the same time. A series of green and red blinks will appear on the Status LED showing the current channel setting. A green blink represents the tens (+10) and a red blink represents the units
(+1).
Examples: 2 green blinks followed by 5 red blinks represents channel 25.
6 red blinks represents channel 06.
+ b. Select a new channel by pressing PB1 and PB2 on the transmitter. Press PB1 to increment the units (+1) and PB2 to increment the tens (+10).
Examples: Press PB2 two times and then PB1 four times will give you channel 24.
Press PB1 nine times with give you channel 09. c. When finished, the newly selected channel will appear on the Status LED via a series of green and red blinks again. d. Exit the channel programming by turning off the transmitter power. e. Make sure the receiver channel is set identical to the transmitter. Please refer to page 29 and page 33 on how to change receiver channel. f. Please note that when the CHANNEL dip-switch inside the transmitter is changed, the priority will revert back to the new channel set on the CHANNEL dip-switch. g. Please note that when channel is set beyond channel 62 via PB1 and PB2 (i.e. channel 63,
68, 88, etc…), the system will recognize it as channel 62.
Flex 12EX System Instruction Manual
December 2013
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4.1.4 Optional 4-Digit Security Code
The 4-digit Security Code is an optional feature that can be programmed into the transmitter to allow operation only to those who know the code. If this feature is desired, set up as follows: Prior to rotating the transmitter power key-switch to START position to begin operation, you first enter a
4-digit security code in order to proceed further. When this 4-digit security code is entered correctly, a green light will appear on the Status LED. Please refer to the instruction below on how to program the 4-digit security code. a. Release E-Stop, then press and hold PB1, PB2, PB3 and PB4 (all at once), and then rotate the power key to START position.
+ b. A constant orange light will appear on the Status LED telling you that you are in the security code programming mode. c. For newly purchased system with the security code function deactivated (default setting), press PB1 four times (1111) to activate the security code function. At this time the Status LED on the transmitter will blink orange slowly telling you that the 4 digits entered is correct. Then select your own 4-digit security code by pressing PB1, PB2, PB3 or PB4 on the transmitter
(four presses randomly). At this time, fast orange blinks are displayed on the Status LED telling you to reconfirm the 4-digit security code you have just entered. A green light will appear once you have re-entered the same 4-digit security code again (programming completed). If any mistake is made during this process, or if a red light is shown on the Status
LED after you have re-entered the security code (incorrect input), or even if you believe you have entered the correct code but the transmitter fails to work properly, then you must reset the transmitter power (by power-cycling the transmitter*) and then repeat step a, b, and c again.
*NOTE: To power-cycle the transmitter, you must first remove, then reinstall the batteries. Simply turning the power switch off, then on will NOT properly clear the memory. This process must be used for any errors regarding proper transmitter operation (not just for security code settings).
Steps: Press and hold PB1~PB4 and rotate power key to START position → constant orange
→ press PB1 four times (for new systems) or 4-digit security code → slow orange blinks → enter the new 4-digit security code → fast orange blinks → re-enter the same 4-digit security code again → green light. d. If you wish to cancel the security code function, then repeat a, b, and c above and press PB1 four times as your new security code (security code function disabled). e. If you do not remember the 4-digit security code, then you must contact your dealer or distributor for further assistance.
Flex 12EX System Instruction Manual
December 2013
Page 27 of 48
4.1.5 I-CHIP
The I-CHIP functions in a way that is very similar to a SIM card inside a mobile phone, which stores system information such as your telephone number, account number, phone book and other settings. The I-CHIP works exactly the same way, as it stores information such as system serial number/ID code, channel and push button configurations.
When replacing a transmitter handset, just take the I-CHIP out of the old transmitter and install it into the new one (refer to Fig. 11 below). For a complete information transfer, make sure both the
Channel and Function dip-switch is set to all “1”. If both dip-switches are set to all “1”, then the transmitter will operate according to the push button configurations and channel stored inside the
I-CHIP. If both the Channel and Function dip-switch is set to other values other than all “1”, then the transmitter will operate according to the channel and push button configurations set on these two dip-switches, not the ones stored inside the I-CHIP. Every time the settings on these two dipswitches are changed, the new settings will be stored into the I-CHIP automatically. In this case the previous channel and push button configurations stored inside the I-CHIP will be erased and be replaced by the new settings.
For safety purposes, the system serial number/ID code stored inside the I-CHIP cannot be changed directly on the transmitter encoder board. Only channels and push button configurations can be changed directly on the encoder board via Channel and Function dipswitches. There are only two ways that you can change a transmitter serial number/ID code: via the I-CHIP programming port located on the decoder module inside the receiver unit, please refer to page 37 on how to program the I-CHIP (serial number/ID code) via receiver unit; or via an external I-CHIP programmer or duplicator unit available from the factory. Please ask your local dealers for assistance if your system requires serial number/ID code adjustments.
(Fig. 11)
Flex 12EX System Instruction Manual
December 2013
Page 28 of 48
4.2 RECEIVER UNIT
4.2.1 System Channel Settings
EXT INT
1 2 3 4 5 6 7 8
(Fig. 12)
Even though the Flex system is equipped with an automatic channel scanning receiver, the user can also set the receiver channel manually. Please refer to page 33 on how the automatic channel scanning receiver works.
Set the receiver channel by adjusting the channel dip-switch located on the receiver module
(refer to Fig. 12 above), only the first six (6) positions are used for channel programming (refer to
Fig. 13 below). The system channels table located on page 38 illustrates which dip-switch setting corresponds to which channel. Once the receiver channel is altered make sure to change the transmitter channel as well. The channel on both the transmitter and receiver must be identical in order for the system to work. To change the transmitter channel please refer to page 17.
Example:
(Fig. 13)
1 2 3 4 5 6 7 8
Top slot → “1”
Bottom slot → “0”
The above dip-switch setting “1 0 0 1 0 0” corresponds to “channel 36” in the system channels table on page 38.
Flex 12EX System Instruction Manual
December 2013
Page 29 of 48
4.2.2 Output Relay Configurations
4.2.2.1 Output Relay Types
1. Three (3) output relays per motion – shared 2 nd speed output relay
Output relays with Forward 1 st
speed (F1), Reverse 1 st
speed (R1) and
Forward/Reverse 2 nd speed (F/R2). Forward and Reverse 2 nd speed (F/R2) share the same output relay.
F1 R1 F/R2
2. Four (4) output relays per motion – separate 1 st and 2 nd speed output relays
Output relays with Forward 1
(F2) and Reverse 2 nd relays. st speed (F1), Reverse 1 st speed (R1), Forward 2 nd speed
speed (R2). Forward and Reverse 2 nd
speed with separate output
F1 R1 F2 R2
4.2.2.2 Output Relay Actions at 2 nd Speed
1. 3-output relays configuration with Closed/Closed contact at 2 nd speed
At 2 nd speed, both 1 st speed (F1 or R1) and 2 nd speed (F/R2) output relays are
closed (refer to page 34 on how to set to this function).
Forward 1 st speed push button pressed Forward 2 nd speed push button pressed
F1 R1
↓
F/R2 F1 R1
↓
F/R2
Flex 12EX System Instruction Manual
December 2013
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2. 4-output relays configuration with Opened/Closed contact at 2 nd speed
At 2 nd
speed, only the 2 nd
speed (F2 or R2) output relay is closed (refer to page 34 on how to set to this function).
F1
Forward 1 st speed push button pressed
R1
↓
F2 R2
Forward 2 nd speed push button pressed
F1 R1
↓
F2 R2
3. 4-output relays configuration with Closed/Closed contact at 2 nd speed
At 2 nd
speed, both 1 st
speed (F1 or R1) and 2 nd
speed (F2 or R2) output relays are closed (refer to page 34 on how to set to this function).
F1
Forward 1 st speed push button pressed
R1
↓
F2 R2
Forward 2 nd speed push button pressed
F1 R1
↓
F2 R2
4.2.2.3 ON/OFF Push Button Function
The user can set any of the two adjacent push buttons on the transmitter to behave like a mechanical ON & OFF rocker switch (refer to page 34 on how to set to this function). When
“On” output relay is closed (“On” push button pressed), the “Off” output relay will open automatically, or vice versa.
OFF ON
Flex 12EX System Instruction Manual
December 2013
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4.2.2.4 START/AUX Function
After initiating the START function the Start position will become an auxiliary function with momentary contact. For auxiliary applications such as a horn or a buzzer, please connect it to the FUNC output relay (wire #6) located inside the receiver unit.
4.2.2.5 Magnet ON/OFF Push Button Function
The user can set any of the two adjacent push buttons on the transmitter to control a magnet. To activate the magnet just press the push button with the Magnet symbol. To deactivate the magnet, for safety purpose, you must first press and hold the Magnet push button and then press the OFF push button. Pressing the OFF push button by itself cannot deactivate the magnet (refer to page 34 on how to set to this function).
OFF
4.2.2.6 Brake Function
When the transmitter push button is released from 2 nd
speed up to 1 st speed output relays will open for up to 1.0 second and then with 1 thereafter (refer to page 34 on how to set to this function). st
speed, both 1 st
and 2 nd
speed output relay closed
When push button is released the output relay corresponds to that push button will open
(refer to page 34 on how to set to this function). This type of contact is usually applies to external application such as horns or buzzers.
4.2.2.8 Toggled Contact
When the push button is released the output relay corresponds to that push button will remain closed (maintained contact) until the next time the user presses the same push button again (refer to page 35 on how to set to this function). This type of contact is usually applied to external application such as lights.
This function allows the crane to travel an additional step beyond 2 the operator is pressing the “UP” push button down to 2 button (with “UP” push button still hold at 2 nd nd speed (refer to page 35 on how to set to this function). nd speed. For example, if
speed, pressing the 3
speed) will toggle between the 2 nd rd
speed push
speed and 3 rd
3rd
SPEED
Flex 12EX System Instruction Manual
December 2013
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4.2.2.10 Auxiliary STOP Push Button Function
The auxiliary STOP function acts as a 2 nd
emergency stop button. Other than by emergency stop button and transmitter power key switch, the receiver MAIN is also deactivated when this auxiliary stop push button is pressed (refer to page 35 on how to set to this function).
Aux
STOP
4.2.2.11 Pitch & Catch Function
This function allows two operators to control one crane from opposite ends of a cross or long travel (refer to page 35 on how to set to this function). When set to “Pitch & Catch” make sure the 2 nd
transmitter is set to the next upper channel (channel X*+1). For example, if the system is preset at “Ch.01” then the channel of the 2 nd
transmitter should be set to
“Ch.02”. Furthermore, the dip-switch position #7 and #8 on the receiving module should be set to “10”, this will allow the receiver to scan only Ch.01 and Ch.02 (please refer to the illustration below). On the other hand, since there are only 62 available channels on the
Flex system, the system preset at channel 62 is ineffective because the 2 nd
transmitter cannot be set to Ch.63. If your system is preset at Ch.62 make sure to change it to another channel.
4.2.3 Receiver Auto-Scanning Settings
Receiver Channel Dip-switch
↓
(1) →
1 2 3 4 5 6 7 8
Scanning all 62 channels (manufacture preset)
For standard operation
Single fixed channel (channel X*)
Auto scanning function disabled
1 2 3 4 5 6 7 8
Scanning 2 channels only (channel X*, channel X*+1)
For Pitch & Catch, Tandem, and Random Access operation
1 2 3 4 5 6 7 8 with 2 receivers
→ Scanning 3 channels only (channel X*, channel X*+1,
X*+2)
1 2 3 4 5 6 7 8
For Random Access operation with 3 receivers
* Channel X → Channel set on the receiving module
Example: If the first 6 dip-switch positions on the receiving module is set to Ch.01
(“000000” or “000001”), when set to 2-channel scanning (type-3 above), then the receiver will only scan Ch.01 and Ch.02.
Flex 12EX System Instruction Manual
December 2013
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4.2.4 Dip-Switch Settings
4.2.4.1 Interlocked Functions
Interlocked means the two adjacent push buttons cannot be activated simultaneously as they will cancel each other out. Interlocked settings are usually applied to a crane’s forward and reverse motions. Each dip-switch on the decoder module corresponds to one (1) motion or two (2) adjacent push buttons (refer to Fig. 14 & 15 below). Only the first seven
(7) dip-switch positions are used (counting from left to right). The 8 th
dip-switch position
(far right) is not used.
1 2 3 4 5 6 7 8
(Fig. 14)
▇ Manufacture preset
Dip
Settings
0000000
0000001
0000010
0000011
RELAY FUNCTIONS (Fig. 15)
Function Descriptions
Normal (single speed only, F2 & R2 relays not used)
Closed/Closed Relay Action at 2 nd Speed (separate 2 nd speed relay)
Closed/Closed Relay Action at 2 nd relay)
Speed (shared 2 nd speed
Opened/Closed Relay Action at 2 nd relay)
Speed (separate 2 nd
speed
# of Relays
Used
2
4
3
4
0000110 On (right button) & Off (left button) 2
0001000
0001001
0001010
0001011
0000111
On & Off affected by the e-stop command. When E-stop command is initiated, the Off relay is activated.
On + Start / Off + Start -- Prior to pressing the button you must first rotate and hold the power key switch at START position to activate On or Off relays.
FWD/REV toggled (latched).
FWD/REV toggled (latched) and affected by the E-stop command.
Safety Magnet On & Off
0100001
0100010
0100011
Closed/Closed + Brake
Closed/Closed Relay Action + Brake
2
2
2
2
2
4
3
Opened/Closed Relay Action + Brake 4
Flex 12EX System Instruction Manual
December 2013
Page 34 of 48
4.2.4.2 Non-Interlocked Functions
Contrary to interlocked settings, non-interlocked settings allow the two adjacent push buttons to be used simultaneously. Non-interlocked settings are usually applied to a crane’s auxiliary functions such as lights, horns, 3 rd
speed, auxiliary stop, and Pitch & Catch. Each dip-switch on the decoder module corresponds to one (1) motion or two (2) adjacent push buttons (left & right push buttons).
Function
Code
Dip
Position
Setting
#1
Dip Position Setting
#2 - #4 (left button)
&
#5 - #7 (right button)
Function Description
A 1
B 1
C 1
D 1
E 1
000
001
010
011
Normal (momentary) contact.
Toggled (latching) contact.
Acceleration (3 rd
speed).
Toggled (latching) contact affected by the
E-Stop command. When E-Stop command is initiated, all toggled (latching) relays are also deactivated.
101
Pitch & Catch Type-1. When Pitch (release) function is initiated, receiver MAIN will not be deactivated.
F 1 110
Pitch & Catch Type-2. When Pitch (release) function is initiated, receiver MAIN will be deactivated.
G 1 111 Auxiliary Stop.
H 1 100
Normal + Start function. For added safety, you must first rotate and hold the power key switch at “START” position and then press the intended push button at the same time to activate the output relay.
Example #1: Left button (set to function code A) / right button (set to function code A) → 1 000 000
Example #2: Left button (set to function code B) / right button (set to function code B) → 1 001 001
Example #3: Left button (set to function code A) / right button (set to function code C) → 1 000 010
Example #4: Left button (set to function code F) / right button (set to function code A) → 1 110 000
Note: When set to Pitch & Catch function make sure the 2 nd transmitter is set to the next upper channel. For example, if the system is preset at Ch.01 then the 2 nd transmitter should be set to Ch.02. Furthermore, you must also set the dip-switch on the receiving module (position #7 & #8) to “10” position (2-channel scanning), please refer to page 33.
Flex 12EX System Instruction Manual
December 2013
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4.2.5 Jumper Settings
Jumper settings are applied to functions such as mainline-disconnect time, Start function, transmitter push button layout, system information (serial number/ID code) programming, and system testing. The jumpers #1 - #7 are located on the decoder module above the six (6) dipswitches (refer to Fig.16 below).
(Fig. 16)
▇ Manufacture preset
Jumper Settings Function
JP1
(Blank)
JP1
(Inserted)
JP1
(Blank)
JP1
(Inserted)
JP2
(Blank)
JP2
(Blank)
JP2
(Inserted)
JP2
(Inserted)
Receiver MAIN remained closed until the transmitter power is turned off or emergency stop command is initiated.
Receiver MAIN opens after 5 minutes of system inactivity.
Receiver MAIN opens after 30 minutes of system inactivity.
Receiver MAIN opens after 60 minutes of system inactivity.
JP3
(Blank)
Press any push button on the transmitter to activate the receiver MAIN at system startup, after e-stop reset, and after system inactivity
(refer to JP1 & JP2 settings above).
JP3
(Inserted)
Rotate the power key switch to “START” position to activate the receiver
MAIN at system startup, after e-stop reset, and after system inactivity
(refer to JP1 & JP2 settings above).
JP4
(Blank)
JP4
(Inserted)
JP4
(Blank)
JP5
(Blank)
JP5
(Blank)
JP5
(Inserted)
Standard right-to-left push button configuration for all models.
In-line push button configuration (top to bottom) for Flex 8ES/EX.
In-line push button configuration (top to bottom) for Flex 12ES/EX.
JP4
(Inserted)
JP5
(Inserted)
JP6
(Blank)
In-line push button configuration (top to bottom) for Flex 4ES/EX.
Program system serial number/ID code and channel from decoder modul to I-CHIP.
JP6
(Inserted)
Program system serial number/ID code and channel from I-CHIP to decoder module.
JP7
(Inserted)
For system test only, receiver MAIN disabled.
Flex 12EX System Instruction Manual
December 2013
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4.2.6 I-CHIP Programming Port
(Fig. 17)
The I-CHIP programming port located on the decoder module (refer to Fig. 17 above) inside the receiver is designed for the purpose of transferring system serial number/ID code either from I-
CHIP to receiver or vice versa. If you wish to transfer system information from receiver to I-CHIP, just insert the I-CHIP onto the programming port (JP6 jumper not inserted), wait until the Status
LED on the decoder module turned constant green (within 2 seconds), and then take the I-CHIP out of the programming port (programming completed). At this time the I-CHIP should also possess the same serial number/ID code as the receiver. If the Status LED on the decoder module displays a constant red light after inserting the I-CHIP (programming failed), then you must reinsert the I-CHIP one more time. On the other hand, if you wish to transfer system information from the I-CHIP to the receiver, then you must first insert JP6 jumper prior to inserting the I-CHIP, then wait for the green light to appear on the Status LED. At this time the receiver should also possess the same system information as the I-CHIP. Please note that the receiver unit must be powered in order to proceed with the programming.
4.2.7 Voltage Settings
Always check the voltage setting is correct for your application prior to installation (refer to Fig. 18 below).
Position → 110~120VAC
Position → 220~240VAC or 24VAC*
Position → 380-400VAC or 42VAC*
Position → 410-460VAC or 48VAC* or 12~24VDC**
* For system with 24/42/48VAC power supply.
** For system with 12~24VDC power supply.
COM 1
(Fig. 18)
2 3 4
F9 and F10 power fuse ratings:
FUSE #
F9
110 -
120VAC
220 -
240VAC
380 -
400VAC
410 -
460VAC
24VAC 42 & 48VAC 12 - 24VDC
1.0A (red) 1.0A (red) 1.0A (red) 0.5A (blue) 3.0A (yellow) 2.0A (purple) 2.0A (purple)
F10 1.0A (red) 1.0A (red) 1.0A (red) 0.5A (blue) 3.0A (yellow) 2.0A (purple) 2.0A (purple)
* Output relay fuse → 5.0A (clear)
Flex 12EX System Instruction Manual
December 2013
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5. SYSTEM CHANNELS TABLE
Channel Frequency
Dip-switch
Setting
Channel Frequency
Dip-switch
Setting
01
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
433.450MHZ
433.475MHZ
433.500MHZ
433.525MHZ
433.550MHZ
433.575MHZ
433.600MHZ
433.625MHZ
433.650MHZ
433.675MHZ
433.700MHZ
433.725MHZ
433.000MHZ 000000 32
433.000MHZ
000001 33
433.025MHZ
433.050MHZ
000010
000011
34
35
433.075MHZ
433.100MHZ
433.125MHZ
433.150MHZ
433.175MHZ
433.200MHZ
433.225MHZ
433.250MHZ
433.275MHZ
433.300MHZ
433.325MHZ
433.350MHZ
433.375MHZ
433.400MHZ
433.425MHZ
000100
000101
000110
000111
001000
001001
001010
001011
001100
001101
001110
001111
010000
010001
010010
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
010011
010100
010101
010110
010111
011000
011001
011010
011011
011100
011101
011110
51
52
53
54
55
56
57
58
59
60
61
62
433.775MHZ
433.800MHZ
433.825MHZ
433.850MHZ
433.875MHZ
433.900MHZ
433.925MHZ
433.950MHZ
433.975MHZ
434.000MHZ
434.025MHZ
434.050MHZ
434.075MHZ
434.100MHZ
434.125MHZ
434.150MHZ
434.175MHZ
434.200MHZ
434.225MHZ
434.250MHZ
434.275MHZ
434.300MHZ
434.325MHZ
434.350MHZ
434.375MHZ
434.400MHZ
434.425MHZ
434.450MHZ
434.475MHZ
434.500MHZ
434.525MHZ
100000
100001
100010
100011
100100
100101
100110
100111
101000
101001
101010
101011
101100
101101
101110
101111
110000
110001
110010
110011
110100
110101
110110
110111
111000
111001
111010
111011
111100
111101
111110
31 433.750MHZ 011111
I-CHIP
* When set to all “1” the priority goes to the channel assigned inside the I-CHIP.
111111*
Flex 12EX System Instruction Manual
December 2013
Page 38 of 48
6. RECEIVER INSTALLATION
6.1 OUTPUT RELAY CONTACT DIAGRAM
* For 3-relay (shared 2 nd
30.
speed) and 4-relay (separate 2 nd
speed) configuration please refer to page
* For 4-relay closed/closed and 4-relay opened/closed relay configuration please refer to pages 30 and 31.
* For different voltage settings please refer to page 37.
* For F9 and F10 power fuse ratings please refer to page 37.
* For 12 - 24VDC power supply, wire #1 corresponds to the negative charge (-) and wire #3 corresponds to the positive charge (+). Wire #2 is for GROUND.
Flex 12EX System Instruction Manual
December 2013
Page 39 of 48
6.2 PRE-INSTALLATION PRECAUTIONS
1. Make sure the transmitter and receiver have identical serial number/ID codes and channels.
2. Make sure the receiver is not set to the same channel as any other systems in use in the
surrounding
3. Make sure that the crane or equipment is working properly prior to installation.
4. Make sure the power source to the receiver is set correctly.
5. Switch off the main power source to the crane or equipment prior to installation.
(Fig. 19)
1. For best reception the location of the receiver should be visible to the operator at all time.
2. The location selected should not be exposed to high levels of electric noise. Mounting the receiver next to an unshielded variable frequency drive may cause minor interference. Always locate the receiver as far away from variable frequency drive as possible.
Flex 12EX System Instruction Manual
December 2013
Page 40 of 48
3. Ensure the selected location has adequate space to accommodate the receiver (refer to Fig. 19 on page 40). If an external antenna is used, to avoid the possibility of antenna damage always locate the receiver where the antenna is free from any obstacles from all directions (refer to diagram at right).
4. When installing an external antenna you must connect the SMA jack located inside the receiver and make sure to set the jumper to “EXT” position (refer to diagram below).
432 mm
Control
Panel
5. For better reception, make sure the receiver is in an upright position.
6. Drill two holes (10mm in diameter) on the control panel or location where the receiver is to be installed (refer to Fig. 19 on page 40).
7. Make sure the two bolts are tightened after installation.
8. For system wiring please refer to page 39.
6.4 SYSTEM TESTING
1. Turn on the power source to the receiver and test the MAIN relay output by pressing the red emergency stop button and observe that it properly opens and closes the mainline disconnect contactor.
2. Test the operation of each function to ensure it corresponds to the transmitter direction labels or the pendant it is replacing.
3. Test the limit switches (if any) to see if they are working properly.
4. If your new remote control is replacing an existing pendant, make sure it is completely disconnected and placed in a safe location to prevent unwanted control commands.
Flex 12EX System Instruction Manual
December 2013
Page 41 of 48
7. OPERATING PROCEDURE
7.1 TRANSMITTER OPERATION
7.1.1 General Operating Procedure
a. 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. b. 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 “On” position. c. After turning on the transmitter power, check the Status LED on the transmitter handset for any sign of system irregularities (refer to “Status Light Indicators & Warnings” on page 45). If the system is normal the Status LED will light up green for two (2) seconds. d. If there are no signs of any system irregularities, then rotate the power key further clockwise to “Start” position for up to 2 seconds. This will activate the receiver MAIN (depends on JP3 setting on page 36). Thereafter, the same “Start” position will become an auxiliary function with momentary contact (refer to page 32).
Flex 12EX System Instruction Manual
December 2013
Page 42 of 48
e. Now press any push button on the transmitter handset to operate the crane or equipment.
During transmitter inactivity (push buttons not pressed), the transmitter will automatically switch to standby mode, with an orange blink on the Status LED every 4-second interval. f. In case of an emergency, pressing down on the red emergency stop button will immediately disconnect the receiver mainline (Status LED blinks red). To reset the emergency stop button just rotate the red button either clockwise or counter-clockwise; it will pop up. When the green light appears, rotate the power key to “Start” position to resume operation (depends on JP3 setting on page 36). g. After 5 minutes of inactivity (push button not pressed) the receiver MAIN will be disconnected temporarily (depends on JP1 & JP2 settings on page 36). To resume operation just rotate the power key switch to START position to reconnect the receiver
MAIN. h. Turn off the transmitter power by rotating the power key counter-clockwise to “Off” position; it will disconnect the transmitter power and the receiver MAIN altogether. Turn it further counter-clockwise to release the key.
7.1.2 A/B Selector Push Button Operating Procedure
Pressing the “Select A/B” push button will toggle between output relay A, B, A+B respectively.
There are 4 different types of Select A/B sequences available; please refer to page 19 for instructions on how to set Select A/B functions.
A
B
7.1.3 3
rd
Speed Push Button Operating Procedure
When a push button is held at 2 nd speed, pressing the 3 rd activate the 3 rd the 3 rd speed output relay (toggled). If the operator wants 2
Speed push button one more time.
Speed push button one time will nd
speed again, just press
3rd
SPEED
Flex 12EX System Instruction Manual
December 2013
Page 43 of 48
7.1.4 Pitch & Catch Operating Procedure
To release control of the crane, press the “Pitch” push button. To take over control of the crane, rotate the power key switch to “Catch” position for up to 2 seconds. The 2 take control of the crane unless the 1 st nd
operator cannot operator presses the “Pitch” push button (2.0 seconds).
If the operator unintentionally presses the “Pitch” push button during operation, just rotate the power key to “Catch” position for up to 2 seconds to regain control again.
→
O
F
ON
CATCH
PI
TC
H
→
C
A
TC
H
C
A
TCH
PIT
C
H
7.1.5 Automatic Channel Scanning Operating Procedure
After changing the transmitter channel (refer to page 17), turn on the transmitter power and rotate the power key switch to “Start” position and hold it there for up to 1 minute. Within this 1minute period the receiver will search (channel 01 ~ channel 62) and lock onto the newly selected transmitter channel automatically. Please note that in order for the receiver to switch to auto-scanning mode, prior to changing the transmitter channel, you must first deactivate the receiver MAIN by shutting off the transmitter power or press down the emergency stop button.
Please refer to page 33 if you do not want the receiver to auto-scan all 62 channels.
Change Transmitter Channel
→
7.1.6 Changing Transmitter Batteries
Change the transmitter batteries by unscrewing the battery cover located on the backside of the transmitter (refer to Fig. 20 below). During battery installation make sure that the blue 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
(Fig. 20)
↓
1
Flex 12EX System Instruction Manual
December 2013
Page 44 of 48
7.2 STATUS LIGHT INDICATORS & WARNINGS
7.2.1Transmitter STATUS Light Indication
Type Indication
1
2
3
4
5
6
7
8
9
10
Constant red
1 red blink followed by a 2second pause
2 red blinks followed by a 2second pause
No light displayed
Voltage goes below 1.9V at initial power on - transmitter power shuts off.
Voltage goes below 1.8V during operation - transmitter power shuts off. Turn the power off to disengage the receiver main.
Voltage goes below 1.85V during operation - change batteries immediately.
The pushbutton is defective after turning on the transmitter power.
When a defective push button condition occurs
(2 red blinks, type 3 above), find out which push button is defective by pressing all the push buttons on the transmitter one at a time. If the push button is in good working order, the LED will not light up when pressed. If the push button is defective the LED will continue to display 2 red blinks when pressed.
3 red blinks followed by a 2second pause
4 red blinks followed by a 2second pause
Constant green for up to 2 seconds
Blinking green
Slow red blinks
1 orange blink every 4 seconds
EEPROM error.
Transmitting error, system can not lock on to the designated channel.
Transmitter power on with no faults detected
(prior to initiating the START function).
Pushbutton pressed, signal transmitted.
Stop command initiated with receiver
MAIN deactivated.
Transmitter on standby.
Flex 12EX System Instruction Manual
December 2013
Page 45 of 48
7.2.2 Receiver STATUS Light Indication
Indication
1
2
3
4
Fast green blinks
Slow green blinks
Slow red blinks
Two red blinks
Decoding in process
Decoding on standby
Stop command initiated with receiver
MAIN deactivated
Receiver MAIN jammed or defective
5
6
Fast red blinks
Constant red
Incorrect transmitter serial number/ID code
Receiver under-voltage, LV output relay activated
Decoding microprocessor is defective 7 No light displayed
7.2.3 Receiver SQ Light Indication
Type Display Indication
1
2
On
Off
Transmission received
No transmission
3 Blinks intermittently
7.2.4 Receiver POWER Light Indication
Other radio interference
1 On Power to receiver
2 Off No power to receiver
7.2.5 Receiver COM Light Indication
Type Display Indication
1
2
On
Off
Power to relay Board
No power to relay board
Flex 12EX System Instruction Manual
December 2013
Page 46 of 48
7.3 TROUBLESHOOTING TIPS
Suggestions
No response when transmitter push button is pressed
(Improper startup & settings)
No response when transmitter push button is pressed
(Damaged hardware)
Transmitter low battery power Check the transmitter battery level.
Emergency stop button activated prior to startup
Improper startup procedure
Incorrect system RF channel
Incorrect system serial number/ID code
System out of range
Defective transmitting and receiving module
Defective encoder board or decoder module
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 serial number/ID code.
Make sure that the startup procedure is initiated within 100 meters (300 feet) from the receiver location.
Check the SQ display on the face of the receiver unit. If it does not light up when the push button is pressed then either the transmitting or receiving module is defective.
First replace the transmitting module. If SQ display is still not lit when the push button is pressed then go ahead and replace the receiving module.
If still no response, then replace the transmitter encoder board. If still doesn’t work then the decoder module is defective.
Incorrect input voltage Make sure the source voltage is set correctly.
No AC power to the receiver
Blown fuse Check for any blown fuse.
Incorrect wiring Check input voltage connection.
Outputs do not correspond to transmitter
Incorrect output connection
Check the system wiring again. Please refer to the output contact diagram inside this manual or on the receiver cover.
Flex 12EX System Instruction Manual
December 2013
Page 47 of 48
8. SYSTEM SPECIFICATIONS
Frequency Range
Frequency
Number
Modulation
: 433 - 434 MHz
:
Manchester
Digital Frequency Modulation based on
20bit
Parity Check and Hamming Code.
Encoder
Transmitting : >100 /
: Synthesized PLL (Phase Lock Loop) Frequency Control
Receiver
Responding 60 Milliseconds (average)
Power : 0.3mW
Enclosure
Enclosure
Output Contact Rating
Transmitter Operating Voltage
:
:
250V @ 8 Amps
DC 3.0V
Receiver
Receiver Supply Voltage : Voltage Setting Min ~ Max
24VAC
42VAC
(22 ~ 26VAC)
(38 ~ 46VAC)
48VAC (43 ~ 53VAC)
110VAC (104
220VAC (207
380VAC (351
410VAC (400
12/24VDC (9 ~ 36VDC)
Operating Temperature
Transmitter Dimension
:
:
-25°C – 75°C / -13°F – 167°F
230mm (L) x 69.0mm (W) x 35mm (H)
Receiver Dimension
Transmitter
: 363mm (L) x 228mm (W) x 70mm (H)
: 2.5kg
Flex 12EX System Instruction Manual
December 2013
Page 48 of 48

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Key features
- 62 user-programmable channels
- Automatic channel scanning receiver
- Over one million unique ID codes
- Advanced microprocessor controls
- Unique I-CHIP design
- Reliable push buttons
- Low power consumption
- Ultra-durable enclosures