Flex Pro Manual
Contents
1. Speed control setting PB1 Decrement Speed Control PB2 Increment Speed Control lt 5 STATUS gt O O O Fig 05 Fig 06 Flex Pro Instruction Manual July 2011 12 of 19 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 Top slot 1 Bottom slot 0 Fig 07 The above dip switch setting 1 0 0 1 0 corresponds to channel 19 in the system channels table on page 14 Flex Pro Instruction Manual July 2011 13 of 19 System Channel Table Channel Frequency euin Channel Frequency QU 01 433 000MHZ 00000 17 433 800MHZ 10000 02 433 050MHZ 00001 18 433 850MHZ 10001 03 433 100MHZ 00010 19 433 900MHZ 10010 04 433 150MHZ 00011 20 433 950MHZ 10011 05 433 200MHZ 00100 21 434 000MHZ 10100 06 433 250MHZ 00101 22 434 050MHZ 10101 07 433 300MHZ 00110 23 434 100MHZ 10110 08 433 350MHZ 00111 24 4342. 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 Flex Pro Instruction Manual July 2011 8 of 19 2 11 SPECIFIC SYSTEM WARNINGS Below are some specific operating safety tips that should be strictly followed when operating a Flex Pro system 1 2 Check the Status LED on the transmitter for any signs of low battery power refer to page 18 Check the Status LED on the transmitter for any signs of irregularities refer to page 18 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 Never operate equipment with two transmitter handsets at the same time unless they are programmed to do so Flex Pro Instruction Manual July 2011 9 of 19 A External Illustration Pro 12 Configuration E Emergency Stop Button S Removable Power Key Switch 1 2 3 4 5 3 General Transmitter Information Fig 01 Push Button 1 Push Button 2 Push Button 3 Push Button 4 Push Button 5 Push Button 6 Push Button 7 Push Button 8 Push Button 9 Push Button 10 Push Button 11 Push Button 12 SC SN RN MN FC NOTE Push Buttons 9 12 are
3. not present on the Flex Pro 8 Module Fig 02 Strap Ring System Information System Channel Crane Number FCC Information Flex Pro Instruction Manual July 2011 10 of 19 B Internal Illustration Pro 12 Configuration Fig 03 Encoder Board Aerial Antenna Transmitting Module Status LED Display Function LED Displays Oo oma NOTE Flex Pro 8 Module will differ slightly COND Fig 04 I CHIP Dip Switch Battery Contact Mechanism Flex Pro Instruction Manual July 2011 11 of 19 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
4. or drugs Flex Pro Instruction Manual July 2011 5 of 19 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 e have knowledge of hazards pertaining to equipment operation e have knowledge of safety rules for radio controlled equipment e have the ability to judge distance of moving objects e know how to properly test prior to operation e 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 e have knowledge of the use of equipment warning lights and alarms e have knowledge of the proper storage space for a radio control transmitter when not in use e be trained in transferring a radio control transmitter to another person e be trained how and when to report unsafe or unusual operating conditions e test the transmitter emergency stop and all warning devices prior to operation testing should be done on each shift without a load e 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 e know how to keep the operator and other people clear of lifted loads and to avoid pinch points e co
5. 150MHZ 10111 09 433 400MHZ 01000 25 434 200MHZ 11000 10 433 450MHZ 01001 26 434 250MHZ 11001 11 433 500MHZ 01010 27 434 300MHZ 11010 12 433 550MHZ 01011 28 434 350MHZ 11011 13 433 600MHZ 01100 29 434 400MHZ 11100 14 433 650MHZ 01101 30 434 450MHZ 11101 15 433 700MHZ 01110 31 434 500MHZ 11110 16 433 750MHZ 01111 32 434 550MHZ 11111 Flex Pro Instruction Manual July 2011 14 of 19 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 Dip Time Out switch Setting 5 minutes 01 10 minutes 10 15 minutes 11 Never shut off 00 Flex Pro Instruction Manual July 2011 15 of 19 5 Operating Procedure General Operating Procedure 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 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 After turning on the transmitter power check the Status LED on the
6. D 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 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 S EL Fig 14 Flex Pro Instruction Manual July 2011 17 of 19 C Status Light Indicators amp Warnings Type Display Type Indication Slow green blink 1 Normal Operation Transmitter on and in standby Button has been pressed and the unit is transmitting 2 Blinking orange The speed at which the orange LED blinks is directly related to how far down the button is pressed 3 1 red blink followed by a 2 Voltage goes below 1 9V during operation second pause change batteries immediately A push button is active while turning on the transmitter 4 2 red blinks followed by a The button that is active will be designated by the 25 2 second pause 50 75 100 LEDs See Push Button Error Table below 5 3 red blinks followed by a I CHIP erro
7. ERATION 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
8. Flex Pro SEN Flex Pro Transmitter Radio Control Equipment Instruction Manual MAGNETEK MATERIAL HANDLING ENRANGE 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 info magnetekmh com Fax Numbers Main 1 800 298 3503 Sales 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 Introduction Radio Controlled Safety General Transmitter Information External Illustration Pro 12 Configuration Internal Illustration Pro 12 Configuration Types of Buttons Adjustable Speed Control oom Dip Switch Settings A System Channel Settings B Inactivity Time Out Operating Procedure Ge
9. 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
10. ist 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 amp TTE and Machinery and Industry Canada Specifications IC Flex Pro Inst
11. ne or hoist Test all warning devices Test all direction and speed controls Test the transmitter emergency stop Flex Pro Instruction Manual July 2011 7 of 19 2 7 BATTERIES N 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
12. neral Operating Procedure Changing Transmitter Batteries Status Light Indicators amp Warnings Push Button Error Table Trouble Shooting Tips moom Page Flex Pro Instruction Manual July 2011 1 of 19 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 e Instructions manuals and safety warnings of the manufacturers of the equipment where the radio system is used e Plant safety rules and procedures of the employers and the owners of facilities where the Magnetek Products are being used e Regulations issued by the Occupational Health and Safety Administration OSHA e Applicable local state or federal codes ordinances standards and requi
13. ntinuously watch and monitor status of lifted loads e know and follow cable and hook inspection procedures e know and follow the local lockout and tagout procedures when servicing radio controlled equipment e know and follow all applicable operating and maintenance manuals safety procedures regulatory requirements and industry standards and codes The operator shall not e liftor move more than the rated load e operate the material handling equipment if the direction of travel or function engaged does not agree with what is indicated on the controller e use the crane hoist or lifting device to lift support or transport people e lift or carry any loads over people e 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 e operate a crane hoist or lifting device if the chain or wire rope is not seated properly in the sprockets drum or sheave e operate any damaged or malfunctioning crane hoist lifting device or other material handling equipment Flex Pro Instruction Manual July 2011 6 of 19 e change any settings or controls without authorization and proper training e remove or obscure any warning or safety labels or tags e leave any load unattended while lifted e leave power on the radio controlled equipment when the equipment is no
14. r 2 second pause 6 4 red blinks followed by a Transmitting error system can not lock on 2 second pause to the designated channel 7 Constant green for up to 2 Transmitter power on with no faults detected prior to seconds initiating the START function Stop command initiated with receiver 8 ole Res ESTOP deactivated Voltage goes below 1 9V at initial power on transmitter 9 pod power shuts off D Push Button Error Table 25 50 75 100 Push Button OFF OFF OFF ON 1 OFF OFF ON OFF 2 OFF OFF ON ON 3 OFF ON OFF OFF 4 OFF ON OFF ON 5 OFF ON ON OFF 6 OFF ON ON ON 7 ON OFF OFF OFF 8 ON OFF OFF ON 9 ON OFF ON OFF 10 ON OFF ON ON 11 ON ON OFF OFF 12 Flex Pro Instruction Manual July 2011 18 of 19 E Trouble Shooting Tips Problems Possible Reasons Suggestions No response when transmitter push button is pressed Improper startup amp settings Transmitter low battery power Check the transmitter battery level Emergency stop button activated prior to startup Prior to turning on the transmitter power switch make sure that the red emergency stop button is elevated Improper startup procedure Redo the startup procedure by holding the power key at START position for up to 2 0 seconds and then release Incorrect system RF channel Make sure that the transmitter handset and
15. rements or e 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 Flex Pro Instruction Manual July 2011 2 of 19 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 amp 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 wa
16. ruction Manual July 2011 3 of 19 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 Flex Pro Instruction Manual July 2011 4 of 19 2 1 CRITICAL INSTALLATION CONSIDERATIONS A WARNING PRIOR TO INSTALLATION AND OP
17. t in operation e operate any material handling equipment using a damaged controller because the unit may be unsafe e operate manual motions with other than manual power e 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 cra
18. the receiver unit both have the same channel Incorrect Receiver Access Code Make sure that the transmitter handset and receiver unit both have the same Receiver Access Code System out of range Make sure that the startup procedure is initiated within 100 meters 300 feet from the receiver location Flex Pro Instruction Manual July 2011 19 of 19
19. transmitter handset for any sign of system irregularities refer to Status Light Indicators amp Warnings on page 18 If the system is normal the Status LED will light up green for two 2 seconds then slowly flash green 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 Flex Pro Instruction Manual July 2011 16 of 19 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 In case of an emergency pressing down on the red emergency stop button will immediately disconnect the receiver E Stop and turn off the unit To reset the emergency stop button just rotate the red button either clockwise or counter clockwise and then cycle power to the unit 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 Turn off the transmitter power by rotating the power key counter clockwise to the Off position Status LE
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