Magnetek Flex 12RS System Instruction manual
Contents
1. DINRAL MOUNTED MODULES 8555 5558 5558 6558 55585558 4 5838 358 5558 5558 9 2 ne 1 DIAGNOSTIC LED S STANDARD DINRAIL FOR MOUNTING BUS CONNECTOR COVER eeee eeecieeec eeceleeecieeee Overall Length 0 89 x N Where N Number of Cards in Systern Length as Required FLEXM 52 Figure 18 Mechanical Layout Flex M 32 Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 22 of 42 FRONT VIEW W DOOR OPEN FRONT VIEW W DOOR OPEN 24 FLEXM 32 TERMINAL BLOCK TERMINAL BLOCK A V n n VIEW JETA VIEW Figure 19 Example of Flex M Receivers Mounted in an Enclosure 7 2 RECEIVER INSTALLATION 1 Be sure to mount the receiver antenna in direct line of sight of the operator and free from all obstructions 2 Do not mount the receiver near high levels of electric noise such as an unshielded variable frequency drive as it may cause minor interference When mounting the Flex M near unshielded variable frequency drive Magnetek typically recommends that the Flex M and all antenna cable routing be mounted a minimum of 24 inches from all unshielded variable frequency drives and cables 3 Allow adequate room for mounting the receiver Make sure to allow a minimum of 5 between the connector and nearest surface to allow for cable harness connections 4 For best recepti2. Figure 1 E Emergency Stop Button S Removable Power Key Switch 1 Push Button 1 2 Push Button 2 3 Push Button 3 4 Push Button 4 5 Push Button 5 NOTES 6 Push Button 6 7 Push Button 7 8 Push Button 8 9 Push Button 9 10 Push Button 10 11 Push Button 11 12 Push Button 12 1 Pushbuttons 9 12 are not present on the Flex 8 PRO Transmitter 2 Pushbutton 7 on the Flex 8PRO and pushbutton 11 on the Flex 12 PRO can be set to A B BOTH Select via dip switch see Section 4 3 Figure 2 SC Strap Ring SN System Information RN System Channel MN Machine Number FC FCC Information Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 13 of 42 3 2 INTERNAL ILLUSTRATION PRO 12 CONFIGURATION Figure 3 Figure 4 Encoder Board 6 Aerial Antenna 7 Dip Switch Transmitting Module 8 Battery Contact Mechanism Status LED Display Function LED Displays Ov Coro c NOTE Flex PRO 8 Module will differ slightly Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 14 of 42 3 3 TYPES OF BUTTONS The buttons used on the Flex Pro are fully proportional stepless push buttons with an output that varies 0 100 based on how far the button is depressed Please consult the factory for more information 3 4 ADJUSTABLE SPEED CONTROL T
3. UP DOW LIE 25 434 200 Mhz UP JP DOWN DOW DOW 26 434 250 Mhz UP UP DOWN DOV 72 434 300 Mhz D JP DOWN 8 DOW 28 434 350 Mhz UP D DOWN L UP 20 434 400 Mhz JP UP DOW DOW 50 434 450 Mhz UP JP UP DO 51 434 500 Mhz UP DOW 52 434 550 Mnz UP UP U UP A33MHz Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 33 of 42 i 10 2 FLEX 24 AND 32 RELAY PRE ENGINEERED WIRING H3LLINSNVeILL JHL NI OL 135 38V SLNdLNO 123135 N3HM 4 NOUNS 3O4 0318 510 OSIY SI LAdLNO 9O1VNV NOILOW YSLLINSNVYL 3Hl NI 3ALOV OL 135 5108110 123135 N3HM 03787510 SI 1ndinO 4 YSLLINSNVYL JHL NI AT3lViMdOSMddV 145 N3HM AINO SLNdINO 123135 51 0 04 NOILO3S 31000W nd9 3N X314 33S M31LINSNVMI X314 OL 440 NMOG 38 LSNW did NV8 April 2012 Page 34 of 42 FLEXM 24 Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual FLEX USLLINSNVAL 3HL NI 3ALLOV OL 13S 5104110 123135 N3HM LL Q318VSId 051 SI LAdLNO 901VNV 9 NOLLOW YSLLINSNVYL NI 3ALLOV OL 13S 5104110 123135 N3HM Q318VSIQ SI 1nd1nO LL USLLINSNVYL AHL NI Ad3lviddOHddV 135 N3HM AINO 33V SLNdLNO 123135 JION
4. Figure 12 Figure 13 3 After turning on the transmitter power check the Status LED on the transmitter handset for any sign of system irregularities refer to Section 11 1 If the system is normal the Status LED will light up green for two 2 seconds then slowly flash green 4 If there are no signs of any system irregularities then rotate the power key further clockwise to the Start position for up to 2 seconds This will activate the receiver E Stop Thereafter the same Start position will become an auxiliary function with momentary contact 4 24 ms SN t WAIN eh oO 0 0 0 a Figure 14 Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 19 of 42 5 Now press any push button on the transmitter handset to operate the equipment When a button is pressed the Status LED will flash orange with a variable speed dependent on how far the button is pressed The further a button is pressed the faster the LED will flash When no buttons are pressed the Status LED will slowly blink green 6 In case of an emergency pressing down on the red emergency stop button will immediately disconnect the receiver E Stop and turn off the unit To reset the emergency stop button just rotate the red button either clockwise or counter clockwise and then cycle power to the unit 7 After a period of inactivity push button not pressed defined by the dip switch
5. Thank you for your purchase of Magnetek s Enrange brand Flex PRO Flex M Radio Remote Equipment Control Magnetek has set a whole new standard in radio remote performance dependability and value with this line of modular receivers If your product ever needs modification or service please contact one of our representatives at the following locations U S Service Information For questions regarding service or technical information contact 1 866 MAG SERV 1 866 624 7378 World Headquarters Magnetek Inc 49 W13650 Campbell Drive Menomonee Falls WI 53051 Phone 1 800 288 8178 Fax 1 800 298 3503 Magnetek Inc has additional satellite locations for Canada and the United States For more information please visit http www magnetekmh com 2012 MAGNETEK All rights reserved This notice applies to all copyrighted materials included with this product including but not limited to this manual and software embodied within the product This manual is intended for the sole use of the person s to whom it was provided and any unauthorized distribution of the manual or dispersal of its contents is strictly forbidden This manual may not be reproduced in whole or in part by any means whatsoever without the expressed written permission of MAGNETEK Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 5 of 42 1 INTRODUCTION The Flex radio remote control systems are designed for control
6. April 2012 Page 30 of 42 OK SOLID Module communication with system good 3 BLINKS Module read write error Possible problem 1 module became disconnected on the bus connector Possible problem 2 CPU module stop running 1 to 8 Indicates Input Output Activity LED INDICATIONS AND MARKINGS Data Bus Connector be set to the same number or letter This is for communication 182 Rotary switch sets the module number No two modules should ic gt between the relay module and CPU rnodule Figure 27 Analog I O Module Detail View MODULE _ 11 Analog Input Analog Output Common 244 Common kel L V 16 2 LI ERE L Bao 1 lt 14 E 2 MTE BH 11 L n Im ANALOG ANALOG E INPUTS OUTPUTS ANALOG 1 0 MODULE 25 02 074 806 Figure 28 Typical Analog I O Wiring Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 31 of 42 10 RECEIVER CHANNEL CONFIGURATION SETTINGS Bank 2 on RF CPU Module The channel can be set on the RF CPU module via the Bank 2 dip switches The following shows the channels or protocols available for each RF CPU Module option NOTE See Section 7 2 for instructions on how to remove the CPU RF module from the din rail and how to remove the PCB from the module housing Flex P
7. LED on the transmitter for any signs of low battery power refer to Section 11 1 2 Check the Status LED on the transmitter for any signs of irregularities refer to Section 11 1 3 Make sure the system is not set to the same channel as any other Flex systems in use within a distance of 300 meters 900 feet 4 Never operate equipment with two transmitter handsets at the same time unless they are programmed to do so 2 13 FLEX M RECEIVER INSTALLATION WARNING BEFORE OPERATING THE RECEIVER FAMILIARIZE YOURSELF WITH ALL SAFETY INFORMATION IN THIS MANUAL APPROPRIATE MANUAL SUPPLEMENTS AND ANY OTHER LOCAL STATE OR FEDERAL RULES OR REGULATIONS ALREADY IN EXISTENCE FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT 2 14 PRE INSTALLATION Transmitter and receiver access code and channel must match before the system will communicate Be aware of other radio channels in the surrounding area set your system to a unique channel Make sure that your equipment is working properly in manual mode prior to system installation Make sure the power to the receiver is the correct voltage Disconnect equipment power prior to system installation Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 12 of 42 3 GENERAL TRANSMITTER INFORMATION 3 1 EXTERNAL ILLUSTRATION PRO 12 CONFIGURATION
8. S1IVL30 3YOW 303 NOILO3S 3 X314 33S X314 OL NO LSNW did FLEXM 32 Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual FLEX 1ZPRO April 2012 Page 35 of 42 10 3 FCC STATEMENTS Compliance Statement Part 15 19 This device complies with Part 15 of FCC rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 This device must accept any interference received including interference that may cause undesired operation Warning Part 15 21 Changes or modifications not expressly approved by the party responsible for compliance should void the user s authority to operate the equipment This portable transmitter with its antenna complies with FCC s RF exposure limits for general population uncontrolled exposure Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 36 of 42 11 TROUBLESHOOTING WARNING THE OPERATOR SHOULD NOT ATTEMPT TO REPAIR ANY RADIO CONTROLLER IF ANY PRODUCT PERFORMANCE OR SAFETY CONCERNS ARE OBSERVED THE EQUIPMENT SHOULD IMMEDIATELY BE TAKEN OUT OF SERVICE AND BE REPORTED TO THE SUPERVISOR DAMAGED AND INOPERABLE RADIO CONTROLLER EQUIPMENT SHOULD BE RETURNED TO MAGNETEK FOR EVALUATION AND REPAIR FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND D
9. batteries The MLC Master Relay turns off during normal operation Error is reset when transmitter issues a start command Inspect serial communication wiring to ensure there are no breaks poor connections or damage to the wiring Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 40 of 42 11 4 ASSEMBLY AND REPLACEMENT PARTS 433MHz Part 15 version 2 RF CPU Module 25 02 074 816E 120VAC Power Supply Module 25 02 074 804E 12VDC 1 5A Power Supply Module 25 02 074 810E 9 36VDC Power Supply Module 25 02 074 820E Relay Module 8 Mechanical relay outputs 25 02 074 805E Analog I O Module 4 0 to 10VDC Outputs and 4 0 to 10VDC Inputs 25 02 074 806E 400MHz Antenna Kit 20 Cable Antenna and Bracket 178 01377 0530 400MHz Antenna Kit 20 Cable 10 Cable Antenna amp Bracket 178 01377 2530 400MHz Antenna Kit 40 Cable Antenna and Bracket 178 01377 0520 400MHz Antenna Kit 40 Cable 10 Cable Antenna amp Bracket 178 01377 2520 NEMA 4 Enclosure Steel 16 x14 x6 for Flex M RX mounted 20 101 0031E Module Replacement Plugs 01 300 0031E Arc Suppressor Snubbers 20 680 0000E Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 41 of 42 12 NOTES Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 42 of 42
10. of industrial equipment and machinery such as overhead traveling cranes jib cranes gantry cranes tower cranes electric hoists winches monorails conveyor belts mining equipment and other material handling equipment where wireless control is preferred Each Flex system consists of a transmitter handset and standard equipped accessories such as a transmitter waist belt spare transmitter power key clear vinyl pouch AA alkaline batteries compass direction decal sheet and user s manual List of notable features include e 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 e Over one million unique ID codes 20bit Each and every Flex system has its own unique ID code no repeats e 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 e 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 e Reliable push buttons The in house designed push buttons are rated for more than one million press cycles e Low power consumption Requires only two AA Alkaline batteries for more than 100 hours of ope
11. 4 AND 32 RELAY PRE ENGINEERED WIRING eee 34 10 9 FG C STATEMENTS eet eerie e e tede Tee be re tel tenus 36 TE TROUBLESHOOTING 37 11 1 TRANSMITTER STATUS LIGHT INDICATORS amp WARNINGS eee 37 11 2 TRANSMITTER PUSH BUTTON ERROR 38 11 3 TROUBLESHOOTING TABLE it eta e e ea ta Oe d Rennes 39 11 4 ASSEMBLY AND REPLACEMENT nennen nenne nennen nns 41 12 NOTES onere eletti teu ei mi A 42 Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 3 of 42 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 handli
12. 42 Problems Possible Reasons Suggestions The transmitter is going in and Move the transmitter and the receiver closer out of range transmitter and together Receiver responds to receiver are on the edge of the Relocate the receiver antenna to where it is in the transmitter transmission range more line of sight with the transmitter inconsistently The antenna and or cable on Inspect the antenna on the receiver for damage the receiver is damaged or and try to place the antenna in a location that is improperly installed visible when operating the equipment at all times The transmitter powered down Extend the inactivity timeout setting for the due to inactivity transmitter The transmitter powered down due to low batteries The RF Message LED stops blinking for more than 3 Radio interference change the system s channel seconds followed by the MLC setting Relay turning off The RF Message LED stopped and the MLC Relay turned off CPU module is resetting Install snubbers across together within 1 sec possibly the coils of all contactors to reduce transient when engaging or disengaging voltages Ensure that the power module has a another relay that is driving a stable power source contactor The serial data timeout error LED LED 5 on the serial communication card is lit Drive serial communication is inactive or was inactive for more than 1 sec MLC Relay turned off together when LED is lit Replace the transmitter s
13. AMAGE TO EQUIPMENT 11 1 TRANSMITTER STATUS LIGHT INDICATORS amp WARNINGS Type Display Type Indication 1 Slow green blink 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 Voltage goes below 1 9V during operation 2 second pause change batteries immediately A push button is active while turning on the transmitter 4 The button that is active will be designated by the 2 Second pause 25 100 LEDs See Push Button Error Table below 5 3 red blinks followed by a 2 second pause error 6 4 red blinks followed by a Transmitting error system cannot 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 5 Solid Reg ESTOP deactivated 9 Solid Red Voltage goes below 1 9V at initial power on transmitter power shuts off Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 37 of 42 11 2 TRANSMITTER PUSH BUTTON ERROR TABLE A B 25 100 Push Button OFF OFF OFF ON 1 OFF
14. AMAGE TO EQUIPMENT 2 6 TRANSMITTER UNIT Transmitter switches should never be mechanically blocked ON or OFF When not in use the operator should turn the transmitter OFF A secure storage space should be provided for the transmitter unit and the transmitter unit should always be placed there when not in use This precaution will help prevent unauthorized people from operating the material handling equipment Spare transmitters should be stored in a secure storage space and only removed from the storage space after the current transmitter in use has been turned OFF taken out of the service area and secured 2 7 PRE OPERATION TEST At the start of each work shift or when a new operator takes control of the crane operators should do as a minimum the following steps before making lifts with any crane or hoist Test all warning devices Test all direction and speed controls Test the transmitter emergency stop Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 10 of 42 2 8 BATTERIES WARNING KNOW AND FOLLOW PROPER BATTERY HANDING CHARING AND DISPOSAL PROCEDURES IMPROPER BATTERY PROCEDURES CAN CAUSE BATTERIES TO EXPLODE OR DO OTHER SERIOUS DAMAGE FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT 2 9 BATTERY HANDLING Use only batteries approved by Magnetek for the specific product Do not dispose of a battery pack in fire
15. ENERAL TRANSMITTER INFORMATION ssssssssssssssssssssssssssssssssssssessssessssssssssesssseessseessseesssnesssseesee 13 3 1 EXTERNAL ILLUSTRATION PRO 12 13 3 2 INTERNAL ILLUSTRATION PRO 12 14 3 3 TYPES OF BUTTONS 222 eret ebur 15 3 4 ADJUSTABLE SPEED CONTBOL 2 2 2 15 4 SWITCH 6 16 44 SYSTEM CHANNEL SETTINGS amatores erie ta ee te 16 4 2 INACTIVITY TIME OUT TIMER tc ue seen T 17 40 ABIBOTHSBDBOT e o c LAE AL ee LL peti Ro etek LE I E 17 5 SYSTEM CHANNEL TABLE ssssssssssssssssssssssssssssssssssssssssseessscessssssssseessseessseessseessstesssseessseessneessanesssseesea 18 6 OPERATING PROCEDURE ssssssssssssssssssssssesssssssssssssssesssseesssesssstesssesssseessseessscessseessseessseessneessaneessseeess 19 6 1 GENERAL OPERATING PROCEDURE sssssssssssssssssssssssssessssutessuesssseesssessssuesssutessstesssteessusessueesn 19 6 2 CHANGING TRANSMITTER BATTERIES 20 7 0 RECEIVER MECHANICAL DRAWINGS sscsssssssssssssssssssssssssssssssssssssesssssssssssssssessseessseessneesssnesssseesee 21 7 4 MECHANICAL LAYOUTS cue Petia aca aed Del
16. Flex PRO Flex M Pre Engineered Radio Control System Part Number 191 00195 1200 April 2012 2012 Magnetek Material Handling TABLE OF CONTENTS JE INTROBUGTION 4s EM 6 2 RADIO CONTROLLED SAFETY esatta tud ed UM DL dE 7 2 1 WARNINGS AND CAUTIONS x thon Are nat 7 2 2 CRITICAL INSTALLATION CONSIDERATIONS 8 cxi me ium pM a ay na 8 2 4 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED 8 2 5 SAFETY INFORMATION AND RECOMMENDED TRAINING FOR RADIO CONTROLLED 222 cuts aD D UN DLE AMORE 9 2 6 TRANSMITTER UNIT 2 25 E IDA e MED 10 2 7 PRE OPERATION TEST batum ei Dale MU M Bee aE 10 amp pu 11 2 9 BATTERY HANDELN bte m esaet te oS ur 11 2 10 BATTERY CHARGING tette hatte mL ives 11 2 nde tel ate esaet D a e LI 11 2 12 SPECIFIC SYSTEM WARNINGS ttt ttt ttt ttt ttt dtt 12 2 13 FLEX M RECEIVER 1 12 2 14 PREJNSTADNSEATION ota 12 3 G
17. OFF ON OFF 2 OFF OFF ON ON 3 OFF ON OFF OFF 4 OFF 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 Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 38 of 42 11 3 TROUBLESHOOTING TABLE Problems Possible Reasons Transmitter low battery power Emergency stop button activated prior to startup No response when transmitter push button is pressed Improper startup amp settings Improper startup procedure Incorrect system RF channel Incorrect Receiver Access Code System out of range Supplied voltage is out of the acceptable range Internal fuse has blown on Receiver will not turn on power supply module 5VDC CPU RELAY LEDs on Power Supply Module do not light up Internal Power supply on PCB has a problem WDG Online LED on CPU RF module is blinking 2 times communication loss with transmitter and RF MSG LED does not blink WDG Online LED on CPU RF module is blinking 1 time normal operating WDG RF MSG LED does not blink and RF Signal strength LEDs are indicating a signal strength WDG Online LED on CPU RF module is blinking 1 time normal operating WDG RF MSG LED does not blink and RF Signal strength LEDs are indicating an erratic signal WDG Online LED on CPU RF module is blinking 3
18. RO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 32 of 42 10 1 CHANNEL DIP SWITCH SETTINGS FOR 433MHz PART 15 version 2 RF CPU MODULE 25 02 074 816E BANK 2 SW ve POSITIONS CHANNEL SW4 SW5 SW6 1 435000 DOWN DOW DOWN DOWNI DOWN 2 433050 2 DOWN DOWN DOWN DOW UP 3 433100 DOWN DOWN DOWN UP DOWN 4 433150 2 DOWN DOWN DOWN UP UP 5 435200 Mhz DOWN DOW UP DOWN DOWN 6 433 250 M hz DO WM DOW MW J B DOW p 433 300 Mhz DOWN DOW UP JP DOW O 433 350 Mhz DOW DOW UP JP P 9 435 400 Mhz DOWI UP DOWN DOWN DOW Q 433 450 Mhz DOWI JP DOWN DOW D 1 433 500 Mhz DOWI UP DOWN JP DOW 2 433 550 2 DOW UP DOWN 5 433 600 Mhz DOW JP DOW DOW 433 650 Mhz DOW D D DOW D 1 DOW U U DOW J 5 433 700 Mhz DOW UP UP JP DOW 6 433 750 Mhz DOW D UP D P 433 800 Mhz UP DOW DOWNDOW DOW 433 850 Mhz UP DOW DOWN DOW UP 433 900 Mz UP OWN UP DOW 20 433 950 Mhz JP DOW DOWN UP JP 21 434 000 Mhz UP DOW DOW 22 434 050 UP DOW UP DOW UP 2 3 434 100 Mhz DOW UP p JOW 24 434150
19. 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 MAGNETS VACUUM LIFTS PUMPS EMERGENCY EQUIPMENT ETC A MECHANICALLY LOCKING INTERMEDIATE RELAY SYSTEM WITH SEPARATE POWER CONSIDERATIONS MUST BE PROVIDED FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT 2 3 GENERAL Radio controlled material handling equipment operates in several directions Cranes hoists lifting devices and other material handling equipment can be large and operate at high speeds Quite frequently the equipment is operated in areas where people are working in close proximity to the material handling equipment The operator must exercise extreme caution at all times Workers must constantly be alert to avoid accidents The following recommendations have been included to indicate how careful and thoughtful actions may prevent injuries damage to equipment or e
20. WDG 2 BLINKS RF communication loss with transmitter 3 BLINKS read write error to another module RF MSG radio frequency messages received typical is 4 10 messages per second confirms communication between transmitter and receiver RF SIGNAL STRENGTH GAUGE measures the strength of the RF communication LED INDICATIONS AND MARKINGS SEE TRANSMITTER SETTING CHART BELOW G Figure 21 RF CPU Module Detail View Bank 1 Dip 1 on the dipswitches is used to set the style of transmitter being used See chart below for proper settings Dip switch BUTTON SETTING Setting 12 Button 1 8 Button 0 E nm H E RF CPU MODULE 433MHz Part 15 version 2 RF CPU Module 25 02 074 816E Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 27 of 42 9 2 FLEX M POWER SUPPLY MODULE The Flex M Power Supply Module converts the supply power to 5VDC power for all the attached Flex M modules This power module has a maximum output supply current of 1000mA There is one Power Supply Module in the Flex M system 5DC CPU SOLID A SVDC output is going to the CPU module Fused Input 5DC RELAY 77 USER SERVICEABLE SOLID A 5VDC output is going to the Relay modules When the LED is off or out there is either a problem with the input voltage to the module or with d power supply locate
21. afety 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 Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 7 of 42 2 2 CRITICAL INSTALLATION CONSIDERATIONS WARNING PRIOR TO INSTALLATION AND OPERATION OF THIS EQUIPMENT READ AND DEVELOP AN UNDERSTANDING OF THE CONTENTS OF THIS MANUAL AND THE OPERATION MANUAL OF THE EQUIPMENT OR DEVICE TO WHICH THIS EQUIPMENT WILL BE INTERFACED FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT ALL EQUIPMENT MUST HAVE A MAINLINE CONTACTOR INSTALLED AND ALL TRACKED CRANES HOISTS LIFTING DEVICES AND SIMILAR EQUIPMENT MUST HAVE A BRAKE INSTALLED FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT AN AUDIBLE AND OR VISUAL WARNING MEANS MUST BE PROVIDED ON ALL REMOTE CONTROLLED EQUIPMENT AS REQUIRED BY CODE REGULATION OR INDUSTRY STANDARD THESE AUDIBLE AND OR VISUAL WARNING DEVICES MUST MEET ALL GOVERNMENTAL REQUIREMENTS FAILURE TO FOLLOW THIS
22. d communication status of the Relay module OK LED Solid indicates module communication with system is good 8 Blinks indicates read write error to attached CPU Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 25 of 42 Additionally there 8 LEDs labeled 1 through 8 on the Analog I O module When the LED is on this indicates that the module is sending receiving a signal on that input or output LED1 Analog Output 1 is Active non zero LED2 Analog Output 2 is Active non zero LED3 Analog Output 3 is Active non zero LED4 Analog Output 4 is Active non zero LED5 Analog Input 1 is Active non zero LED6 Analog Input 2 is Active non zero LED7 Analog Input 3 is Active non zero LED8 Analog Input 4 is Active non zero Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 26 of 42 9 FLEX MODULE TYPES The Flex M system comprises of a RF CPU module and a power supply module with application specific add on cards in between the CPU module and power supply module 9 1 FLEX RF CPU MODULE The Flex RF CPU Module is the main module that receives radio signals from a paired transmitter and interprets those signals into the appropriate response from the attached I O modules There is one RF CPU module in the Flex M System LED INDICATIONS WDG ONLINE LED SOLID RF communication with transmitter 1 BLINK normal operating
23. d on the PCB LED INDICATIONS AND MARKINGS __ Bus Connector Power Supply Notes Depending upon the application there could be either an AC power supply or DC power supply Figure 22 Power Supply Module Detail View Not Used gt lt _ 120VAC L Not Used sk VDC Not Used 21 gt 120VAC L Not Used X lt Not Used 2 5 7 120VAC Not Used 2 amp 2 COM GND lt Ss 120VAC GND K COM 120 POWER MODULE ion Figure 23 Typical 120VAC Power Wiring Figure 24 Typical VDC Power Wiring NOTES 1 Although the power module has built in protection Magnetek strongly recommends the use of external fuses and circuit disconnects for all Flex modules 2 The built in fuse is not user serviceable but can be checked if troubleshooting To check the fuse remove the power module from the din rail as described in Section 7 2 After removing the module from the din rail press in the tabs as noted above to remove the PCB from the housing The fuse is location is shown in the PCB view above Use a multimeter to check for continuity across the fuse If the fuse is blown contact Magnetek to send the module in for service 3 The total system Current Consumption should not exceed the Maximum Output Supply Current of the power supply module If additional supply current is required contact the factory for a custom so
24. e and CPU module Figure 25 Relay Module Detail View Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 29 of 42 Relay 8 ud Input Power gt de A 355 Relay Output 8 Relay 7 _ Input Power lt 7 Relay Output 7 Relay 6 Input Power SK Sho gt Relay Output 6 Relay 5 m Input Power 24 A gt Relay Output 5 5 Relay Output 4 Relays 1 4 16 Shak Input Power 157 14 3 2 Relay Output 3 lt 5 2_ Relay Output 2 gt Relay Output 1 RELAY MODUL Figure 26 Typical Relay Wiring 9 4 FLEX M ANALOG I O MODULE Outputs The four analog output signals are able to send voltage signals from 0 to 10VDC at an 8bit resolution These outputs are for reference voltage only so each one can only supply 20mA of current The outputs share a common ground reference which is isolated from the Flex M system ground and any additional I O card output ground These outputs can be preconfigured at the factory for different voltage ranges ex 0 5VDC or 3 6 9VDC Inputs The four analog input signals are able to receive voltage signals from 0 to 10VDC at an 8bit resolution The input impedance is 20K for these inputs The inputs share a common ground reference which is shared with the Flex M system ground Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual
25. eing 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 betrained in transferring a radio control transmitter to another person 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 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 e continuously watch and monitor status of lifted loads e know and follow cable and hook inspection procedures 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 carry any loads over people e operate the crane hois
26. he proportional buttons normally operate on a scale from 0 100 but can also be scaled down to operate linearly from 0 25 over the full motion of the button This gives the user more control over lower speeds To adjust the speed control settings press and hold the Start button then press push button 1 or push button 2 to decrement increment the range percentage The red LEDs which indicate the Speed Setting will then change to reflect the current setting Start 4 Speed control setting PB1 Decrement Speed Control PB2 Increment Speed Control ES 4 it 72 SN MC PB2 5 1 lt lt 7 t 3 Lc 7 2 V YE H 8 HX A STATUS 5 100 SS D d Figure 5 6 Flex PRO Flex Pre Engineered Radio Control System Instruction Manual April 2012 Page 15 of 42 4 DIP SWITCH SETTINGS 4 1 SYSTEM CHANNEL SETTINGS Set the transmitter channel by adjusting the channel dip switch located on the backside of the transmitter encoder board refer to Figure 7 below Only the first five 5 positions of the dip switch are used for channel programming refer to Figure 8 below The system channels table Section 5 illustrates which dip switch setting corresponds to which channel Once the transmitter channel is altered you must set up the receiver to recognize the transmitters on its new channel mA T
27. irst ensure all power to the Flex M modules has been turned off and proper lockout tagout procedures have been followed 2 Remove one end rail clamp and un nest the module that you wish to remove by separating it from the others on the rail 3 Use a slotted screwdriver to lift the exposed metal tab ring on the top of the module Swing the module down away from the top tab ring and unhook from the rail 4 The PCB from any module can be removed from its housing by pressing in both tabs first tabs are on the front and back sides of the housing then the top housing and PCB can be removed from the lower housing see Figure 20 for details Notes In order to set dip switches the top along with the printed circuit board need to be removed from the base enclosure Press in the tabs as shown below to remove the printed circuit board Press in both tabs then pul out PCB amp EJ E EJ EJ E E E E m E tr lt RF sena Flex Serles Figure 20 Flex M Housing Removal Detail Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 24 of 42 8 NORMAL OPERATION During the operation of the receiver following the LED indicators will allow observation of the status of the Flex M receiver 8 1 POWER SUPPLY MODULE When the Flex M system has power supplied the two LEDs on the power supply module should be lit and solid 5VDC CPU indicates that 5VDC power i
28. it may explode Do not attempt to open the battery pack Do not short circuit the battery For intrinsically safe environments only use specified Magnetek intrinsically safe batteries Keep the battery pack environment cool during charging operation and storage i e not in direct sunlight or close to a heating source 2 10 BATTERY CHARGING For those transmitters equipped with battery chargers please familiarize all users with the instructions of the charger before attempting to use Do not attempt to charge non rechargeable battery packs Avoid charging partially discharged rechargeable batteries to help prolong battery cycle life Avoid charging the battery pack for more than 24 hours at a time Do not charge batteries in a hazardous environment Do not short the charger Do not attempt to charge a damaged battery Use only Magnetek approved chargers for the appropriate battery pack Do not attempt to use a battery that is leaking swollen or corroded Charger units are not intended for outdoor use Use only indoors 2 11 BATTERY DISPOSAL Before disposing of batteries consult local and governmental regulatory requirements for proper disposal procedure Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 11 of 42 2 12 SPECIFIC SYSTEM WARNINGS Below are some specific operating safety tips that should be strictly followed when operating a Flex Pro system 1 Check the Status
29. l n tte la 21 7 2 RECEIVER INSTALLATION bte 23 T3 REMOVA Sco ey ie Ee art AM iA Lu 24 8 NORMAL OPERATION sssssssssssssssssssssssssssssesssssssssssssssessssesssseessstessssesssseessseessseessseessseessseessneessanesssseeess 25 8 1 POWER SUPPLY MODULE 2 Len ons oe at el e tat b tuer btt 25 82 6550 eas DE D ELE 25 GRE AVM DOES 4 292522 Or d uod d acl D 25 8 4 ANALOG I O MODULE S reta ettet RU RU Dun DUM ue 25 9 FLEX MODULE TYPES ccssssssssssssssssssssssssssssssssssssssssssessssessssesssstessssesssseessseessueessatesssseessueessneessanesssseeess 27 9 1 FLEX RF CPU MODULE 27 9 2 FLEX M POWER SUPPLY 28 9 3 FLEX M RELAY MODUEE inim eI 29 9 4 FLEX M ANALOG IIO MODULE 30 Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 2 of 42 10 RECEIVER CHANNEL CONFIGURATION SETTINGS BANK 2 ON RF CPU MODULE 32 10 1 CHANNEL DIP SWITCH SETTINGS FOR 433MHz PART 15 VERSION 2 RF CPU MODULE 25 02 074 816E ion iae red e ate tee Petite en bd p RE Tet eee 33 10 2 FLEX M 2
30. lution Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 28 of 42 POWER SUPPLY MODULE OPTIONS Minimum Max Output Current Description Transformer Power Part Number Rating 120VAC Power Supply 15VA 1000mA 25 02 074 804 9 18 VDC 1 5A 25VA 1500mA 25 02 074 810 Power Supply Module 9 36VDC Power Supply 15VA 1000mA 25 02 074 820 9 3 FLEX M RELAY MODULE The Flex M Relay module allows the control of high current power up to 5A for attached equipment through 8 relay outputs Four relays have a common power input and four relays have individually separate power inputs The relay module number is set by the rotary switch located on the lower left corner of the board Fused Output S for relays USER SERVICEABLE MODULE NUMBER This number needs to match the internal selector switch setting OK SOLID Module communication with system good 3 BUNKS Module read write error Possible problem 1 module became disconnected on the bus connector Numbers refer to _ Possible problem 2 CPU module stop running relay and pin output R1 to RB number on the connector Indicates relay closure LED INDICATIONS AND MARKINGS Flex M Sees Data Bus Connector peed ooo Rotary switch sets the module number No two modules should be set to the same number or letter This is for communication between the relay modul
31. ng 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 requirements 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 Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 4 of 42 Your New Flex PRO Flex M Radio Control System
32. on and to help protect connectors from moisture and water damage mount the receiver in an upright position Mount with back flush against a flat surface to protect vents from spray 5 If obstructions cannot be cleared or the unit must be mounted inside a metal enclosure the remote antenna should be used see Figure 19 6 Do not enclose the antenna in steel For the best reception keep all metal objects away from the antenna Consult the factory for more information regarding your application T The supply power to the Flex M system must have a master disconnect and should be fused 8 The Flex M modules are installed on a 35mm din rail To install the individual modules on the din rail hook the bottom of the module on the din rail and swing the top of the module to the rail until a click is heard or felt 9 After the modules are placed on the rail they are slid together so they nest together Rail clamps are suggested to prevent the module bundle from sliding freely on the rail 10 Modules MUST be installed so that the RF CPU module is on the left end of the rail and the power supply module is on the right end of the rail NOTE Magnetek strongly recommends the use of external fuses and circuit disconnects for all Flex Modules Consult factory for more information Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 23 of 42 7 3 REMOVAL 1 To remove modules from the rail for service f
33. opslot 1 12345678 Bottom slot gt 0 Figure 7 Figure 8 The above dip switch setting 1 0 0 1 0 corresponds to channel 19 in the system channels table Section 5 Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 16 of 42 4 2 INACTIVITY TIME OUT TIMER Bits 6 and 7 on the dip switch allows the user to define a time after which if no buttons on the transmitter are pressed the Flex Pro will send an OFF command to the receiver and power down To restart the user must turn the On Off Start switch to the Off position then back to On again to resume operation Time Out persa 5 minutes 01 10 minutes 10 15 minutes 11 Never shut off 00 4 3 A B BOTH SELECT Es 123456 Figure 9 Bit 8 on the dip switch allows the user to set the lower left pushbutton PB7 on the Flex 8 PRO PB11 on the Flex 12 PRO into an A B BOTH Select button When the B BOTH Select button is enabled it can be used to toggle through the desired outputs as follows A gt gt Dip switch A B BOTH Setting Enabled 1 Disabled 0 12345678 Figure 10 NOTE When A B Select function is Enabled A B LEDs will be OFF at initial startup but will remain ON A B or BOTH once selected When A B Select function is disabled A B LEDs will remain OFF Flex PRO Fle
34. rating time between replacements e Ultra durable nylon and fiberglass composite enclosures Highly resistant to breakage and deformation even in the most abusive environments e Full compliance All systems are fully compliant with the FCC Part 15 Rules and Industry Canada Specifications IC e System Versatility The Flex PRO Flex M Radio Control Systems are able to control up to 4 motions or 3 motions with A B Select with the Flex 8 PRO transmitter or up to 6 motions or 5 motions with A B Select with the Flex 12 PRO transmitter Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 6 of 42 2 RADIO CONTROLLED SAFETY 2 1 WARNINGS AND CAUTIONS Throughout this document WARNING and CAUTION statements have been deliberately placed to highlight items critical to the protection of personnel and equipment WARNING A warning highlights an essential operating or maintenance procedure practice etc which if not strictly observed could result in injury or death of personnel or long term physical hazards Warnings are highlighted as shown below WARNING CAUTION A caution highlights an essential operating or maintenance procedure practice etc which if not strictly observed could result in damage to or destruction of equipment or loss of functional effectiveness Cautions are highlighted as shown below CAUTION WARNINGS and CAUTIONS SHOULD NEVER BE DISREGARDED The s
35. s going to the CPU 5VDC RELAY indicates that 5VDC power is going to the RELAY modules 8 2 RF CPU MODULE When the Flex M system is supplying power to the RF CPU module there is a series of LEDs that will indicate the RF CPU module s status WDG ONLINE LED Solid indicates RF communication with transmitter 1 Blink indicates normal operating WDG 2 Blinks indicates RF communication loss with transmitter 8 Blinks indicates read write error to an attached Flex M module RF MSG LED Fast Blinks indicates radio frequency messages received typical is 4 to 10 messages per second This confirms communication between transmitter and receiver Steady Blinks indicates read write error to an attached Flex M module 4 Steady Blinks indicates an internal radio error RF SIGNAL LED measures the strength of the RF communication signal from the transmitter 8 3 RELAY MODULE S When the Flex M system is supplying power to the Relay module there is an LED that indicates the power and communication status of the Relay module OK LED Solid indicates module communication with system is good 8 Blinks indicates read write error to attached CPU Additionally there are 8 LEDs labeled 1 through 8 on the Relay module When the LED is on this indicates that the relay is closed activated 8 4 ANALOG I O MODULE S When the Flex M system is supplying power to the Analog I O module there is an LED that indicates the power an
36. t or lifting device unless all persons including the operator are and remain clear of the supported load and any potential pinch points Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 9 of 42 operate a crane hoist or lifting device when the device is not centered over the load operate a crane hoist or lifting device if the chain or wire rope is not seated properly in the sprockets drum or sheave e 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 e leave any load unattended while lifted e leave power on the radio controlled equipment when the equipment is not 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 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 D
37. the receiver E Stop will be disconnected and the unit must cycle power before turning on again 8 Turn off the transmitter power by rotating the power key counter clockwise to the Off position Status LED becomes a solid red for 4 seconds This will disconnect the transmitter power and the receiver E Stop altogether Turn it further counter clockwise to release the key 6 2 CHANGING TRANSMITTER BATTERIES Change the transmitter batteries by unscrewing the battery cover located on the backside of the transmitter refer to Figures 15 and 16 below During battery installation make sure that the ribbon is centered between the two batteries After changing the batteries also make sure that all screws are tightened to avoid water moisture dirt grease or other liquid penetration Figure 15 Figure 16 Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 20 of 42 7 0 RECEIVER MECHANICAL DRAWINGS 7 1 MECHANICAL LAYOUTS DINRAIL MOUNTED MODULES 5868 5555 558 5558 5558 E3 6855 8554 5558 5555 STANDARD DINRAIL FOR MOUNTING 2 25825 52 BUS CONNECTOR COVER eeec eeee eeec eeeceeeg Overall Length 0 89 x N Where N Number Cards n System Length as Required FLEXM 24 Figure 17 Mechanical Layout Flex M 24 Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 21 of 42 TNC ANTENNA CONNECTION Et
38. times read write error with relay modules The antenna on the receiver is missing damaged or improperly installed Receiver will not respond to the transmitter Check the transmitter battery level Prior to turning on the transmitter power switch make sure that the red emergency stop button is elevated Redo the startup procedure by holding the power key at START position for up to 2 0 seconds and then release Make sure that the transmitter handset and the receiver unit both have the same channel Make sure that the transmitter handset and receiver unit both have the same Receiver Access Code Make sure that the startup procedure is initiated within 100 meters 300 feet from the receiver location Ensure the voltage is 120VAC nominal Contact the factory for repair Contact the factory for repair Make sure the receiver and transmitter unit are both within range Also verify that the transmitter is still on Make sure the receiver and transmitter unit have the same access code Make sure the receiver and transmitter are both set to the same channel Make sure that the modules are securely put together if the problem persists contact factory for repair Inspect the antenna on the receiver for damage and try to place the antenna in a location that is visible when operating the equipment at all times Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 39 of
39. ven save a life 2 4 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED CRANES Only properly trained persons designated by management should be permitted to operate radio controlled equipment Radio controlled cranes hoists lifting devices and other material handling equipment should not be operated by any person who cannot read or understand signs notices and operating instructions that pertain to the equipment Radio controlled equipment should not be operated by any person with insufficient eyesight or hearing or by any person who may be suffering from a disorder or illness is taking any medication that may cause loss of equipment control or is under the influence of alcohol or drugs Flex PRO Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 8 of 42 2 5 SAFETY INFORMATION AND RECOMMENDED TRAINING FOR RADIO CONTROLLED EQUIPMENT OPERATORS Anyone being trained to operate radio controlled equipment should possess as a minimum the following knowledge and skills before using the radio controlled equipment The operator should have knowledge of hazards pertaining to equipment operation have knowledge of safety rules for radio controlled equipment e have the ability to judge distance of moving objects know how to properly test prior to operation in the safe operation of the radio transmitter as it pertains to the crane hoist lifting device or other material handling equipment b
40. x M Pre Engineered Radio Control System Instruction Manual April 2012 Page 17 of 42 5 SYSTEM CHANNEL TABLE Channel Frequency prs Channel Frequency 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 24 434 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 Flex M Pre Engineered Radio Control System Instruction Manual April 2012 Page 18 of 42 6 OPERATING PROCEDURE 6 1 GENERAL OPERATING PROCEDURE 1 Reset the red emergency stop button located on the top left hand side of the transmitter handset by rotating it either clockwise or counter clockwise The red button will pop up Figure 11 2 Turn on the transmitter power by inserting the black colored key into the power key slot located on the top right hand side of the transmitter handset and rotate it clockwise to the position
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