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Magnetek Flex 12EX2 Instruction Manual - 2.5 Transmitter Unit

Manual is about: Flex 12EX Gen2 series Radio Control Equipment

Summary of Flex 12EX2

  • Page 1

    Flex 12ex gen2 system radio control equipment instruction manual part number: 191-51200-m000f r00 november 2017 ©copyright 2017 magnetek material handling.

  • Page 2

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 2 of 56 page intentionally left blank.

  • Page 3: Table of Contents

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 3 of 56 table of contents service information ............................................................................................................................5 product manual safety information ........................

  • Page 4

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 4 of 56 6.2 master/master tandem operation (tandem systems only)......................................................49 6.3 master/slave tandem operation (tandem systems only)......................................................

  • Page 5: Service Information

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 5 of 56 service information your new radio remote control system thank you for your purchase of magnetek’s flex ex2 radio remote equipment control. Magnetek has set a whole new standard in radio remote performance, dependabilit...

  • Page 6: Warranty Information

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 6 of 56 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 overhead material h...

  • Page 7: 1 Introduction

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 7 of 56 1 introduction the flex ex2 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, winche...

  • Page 8: 2 Radio Controlled Safety

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 8 of 56 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. Note: a not...

  • Page 9: 2.2 General

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 9 of 56 2.1 critical installation considerations 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 ca...

  • Page 10

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 10 of 56 radio controlled equipment should not be operated by any person with insufficient eyesight or hearing or by any person who may be suffering from a disorder or illness that may cause them to lose control of the equipmen...

  • Page 11: 2.5 Transmitter Unit

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 11 of 56 • 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 ...

  • Page 12: 3.1 Transmitter

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 12 of 56 3 general system information 3.1 transmitter 3.1.1 external illustration note: flex 12ex2-ab and 12ex2-t models have the a/b/a+b rotary switch on pb12 slot. 1. Stop button 11. Pushbutton 8 (pb8) 2. Power key switch 12....

  • Page 13

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 13 of 56 3.1.2 internal illustration note: flex 12ex2-ab and 12ex2-t models have the a/b/a+b rotary switch on pb12 slot. 1. Rf transceiver board 5. Infrared sensors 2. Encoder board 6. I-chip slot 3. Status led indicator 7. Fun...

  • Page 14: 3.2 Receiver

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 14 of 56 3.2 receiver 3.2.1 external illustration 1. External antenna port (optional) 7. Remote pairing button 2. Com led indicator 8. System information 3. Status led indicator 9. Cord grip 4. Power led indicator 10. Mounting ...

  • Page 15

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 15 of 56 3.2.2 internal illustration 1. Decoder board 6. Function jumpers 2. Rf transceiver board 7. Channel dipswitch 3. Int/ext antenna jumpers 8. Ac line filter/relay board 4. Programming port 9. Power transformer 5. Functio...

  • Page 16: 4 Function Settings

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 16 of 56 4 function settings 4.1 transmitter 4.1.1 transmitter firmware version 1. Rotate the power switch key to off ( 0 ) position. 2. With the stop button elevated, press and hold pb1 and pb3 at the same time. 3. Rotate the ...

  • Page 17

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 17 of 56 b. Assigned channel scheme (preset system channel) both transmitter and receiver is assigned with a matching preset channel (channel 01 - 62). Note: pitch and catch, tandem, and receiver select configurations must be s...

  • Page 18: →

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 18 of 56 4.1.3 remote pairing a. Transmitter-to-transmitter pairing: 1. Rotate the power switch key to off ( 0 ) position. 2. With the stop button elevated, press and hold pb1 and pb3 at the same time. 3. Rotate the power switc...

  • Page 19: →

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 19 of 56 b. Receiver-to-transmitter pairing: jp8 open method: after the transmitter enters the remote pairing mode, output receiver data by pressing and holding the pairing button located on the receiver cover and receive data ...

  • Page 20

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 20 of 56 4.1.5 transmitter start function settings when transmitter goes into sleep mode the system is temporarily deactivated (main relays opened). Execute the start command or press any pushbutton to wake up the system (main ...

  • Page 21

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 21 of 56 4.1.7 transmitter output power settings 1mw offers the shortest operating range with lowest battery consumption while 10mw offers the longest operating range with highest battery consumption (manufacture preset at 1mw)...

  • Page 22

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 22 of 56 4.1.9.1 toggled pushbutton with led indication – standard right/left pushbutton configuration set pushbutton toggled function (latching output relay) with led indications. Led 1 - 4 shown inside the shaded box illustra...

  • Page 23

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 23 of 56 4.1.9.2 a/b pushbutton select with led indication – standard right/left pushbutton configuration there are 4 different types of a/b selector sequence available. Choose one that is most suitable for your application. Se...

  • Page 24

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 24 of 56 * pb9…pb12 → pushbutton number. * normal → normal momentary contact. * a/1&2 - d/3&4 → a/b pushbutton select function with designated led indication. 86 8 greens + 6 reds normal normal d/1&2 normal 87 8 greens + 7 reds...

  • Page 25

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 25 of 56 4.1.9.3 toggled pushbutton with led indication – inline top/bottom pushbutton configuration set pushbutton toggled function (latching output relay) with led indications. Led 1 - 4 shown inside the shaded box illustrate...

  • Page 26

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 26 of 56 4.1.9.4 a/b pushbutton select with led indication – inline top/bottom pushbutton configuration there are 4 different types of a/b selector sequence available. Choose one that is most suitable for your application. See ...

  • Page 27

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 27 of 56 126 1 orange + 2 greens + 6 reds c/1&2 c/3&4 normal normal 127 1 orange + 2 greens + 7 reds c/1&2 d/3&4 normal normal 128 1 orange + 2 greens + 8 reds d/1&2 d/3&4 normal normal 143 1 orange + 4 greens + 3 reds normal n...

  • Page 28

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 28 of 56 * pb9…pb12 → pushbutton number. * normal → normal momentary contact. * a/1&2 - d/3&4 → a/b pushbutton select function with designated led indication. 4.1.10 display frequency band 1. Rotate the power switch key to off ...

  • Page 29

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 29 of 56 4.1.12 zero-g sensor settings the transmitter is embedded with a zero-g sensor to guard against any unintended control of the crane or equipment when transmitter is thrown or dropped. When triggered, the receiver main ...

  • Page 30

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 30 of 56 type e: a, b, c, d receiver select with bridge receiver type f: a, b, c, d receiver select with bridge 1, 2 select.

  • Page 31: 4.2 Receiver

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 31 of 56 4.2 receiver 4.2.1 receiver channel settings set the receiver channel by configuring the channel dipswitch located on the decoder board. Only the first 6 dip positions are used for channel programming. The system chann...

  • Page 32

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 32 of 56 3. 4 output relays per motion – separate 1st and 2nd speed output relays output relays with forward 1st speed (f1), reverse 1st speed (r1), forward 2nd speed (f2) and reverse 2nd speed (r2). Forward and reverse 2nd spe...

  • Page 33

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 33 of 56 3. 4 output relays configuration with closed/closed contact at 2nd speed f1 (or r1) output relay closed at 1st speed and f1 + f2 (or r1 + r2) output relays closed at 2nd speed. See section 4.2.3.1 on page 36 on how to ...

  • Page 34

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 34 of 56 4.2.2.3 start + aux function after executing the start command at transmitter startup the same start position becomes an auxiliary function with momentary contact connected through k25 function output relay. There are ...

  • Page 35

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 35 of 56 4.2.2.9 pitch & catch function this function allows two operators controlling from opposite ends of a crane or equipment. When set to “pitch & catch” make sure the 2nd transmitter is set to the next highest channel (ch...

  • Page 36

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 36 of 56 4.2.3 dipswitch settings 4.2.3.1 interlocked pushbutton pair interlocked means any pushbutton pair cannot be pressed simultaneously as each press will cancel the other out. Interlocked setting usually applies to electr...

  • Page 37

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 37 of 56 * external warning function requires installing an external warning device such as horn or lights to the k26 function output relay. 4.2.3.2 non-interlocked pushbutton pair non-interlocked setting allows the pushbutton ...

  • Page 38

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 38 of 56 example #1: left button (set to function code a) / right button (set to function code b) → 1 000 001 example #2: left button (set to function code c) / right button (set to function code d) → 1 011 100 function code di...

  • Page 39

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 39 of 56 4.2.4 jumper settings jumper setting applies to functions such as the standard or reversed logic a/b selector sequence, transmitter inline pushbutton configurations, firmware version, system testing and remote pairing ...

  • Page 40

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 40 of 56 4.2.5 voltage settings prior to installation always check to make sure the voltage setting is correct for your application. Position 1 → 110 - 120vac position 2 → 220 - 240vac or 48vac* or 24vac** position 3 → 380 - 40...

  • Page 41

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 41 of 56 4.2.7 other function output relays settings listed below are other types of functions that can be outputted through the three function output relays (k25, k26 and k30) via the infrared ir programmer unit. Contact magne...

  • Page 42

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 42 of 56 type f: a, b, c, d receiver select with bridge 1, 2 select -12 button transmitter (bottom six buttons for a, b, c, d, 1, 2 select) -6 receivers (a, b, c, d, bridge-1 and bridge-2) note: all settings are preset at the f...

  • Page 43

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 43 of 56 4.2.9 system channels table the following dipswitch settings only apply to setting the channel in the receiver when using the assigned channel scheme (see section 4.2.1 on page 31). For information on setting the trans...

  • Page 44: 5 Receiver Installation

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 44 of 56 5 receiver installation 5.1 output relay contact diagrams 5.1.1 flex 12ex2 (dual speed model) for 9 - 36vdc power supply, wire #1 corresponds to the negative charge (-), wire #3 corresponds to the positive charge (+), ...

  • Page 45

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 45 of 56 5.3 step-by-step installation mounting bracket type 1 mounting bracket type 2.

  • Page 46

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 46 of 56 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 unshie...

  • Page 47

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 47 of 56 install ! ! Mounting bracket type 1 mounting bracket type 2 ! ! ! ! !! ! ! ! ! ! ! ! ! ! ! Remove ! ! Mounting bracket type 1 mounting bracket type 2 ! ! ! ! ! ! ! ! ! ! ! ! !.

  • Page 48: 6 Operating Procedures

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 48 of 56 6 operating procedures 6.1 general operation 1. Reset the stop button located on the top left hand corner of the transmitter by rotating it clockwise or counterclockwise; the button will pop up. Turn on the transmitter...

  • Page 49: Only)

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 49 of 56 7. Turn off the transmitter power by rotating the power switch key counterclockwise to off ( 0 ) position; it will disconnect the transmitter power and the receiver main relays altogether. Turn it further counterclockw...

  • Page 50

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 50 of 56 2. Once the transmitter is locked on to both receivers, rotate the selector switch to either a, b, or a+b position for independent or simultaneous operation. 3. At the beginning of each shift prior to turning on the tr...

  • Page 51: Only)

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 51 of 56 6.3 master/slave tandem operation (tandem systems only) 1. To gain control of one or both receivers, first rotate the selector switch to either a, b or a+b position and then execute the start command to activate the re...

  • Page 52

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 52 of 56 2. Once the transmitter is locked on to both receivers, rotate the selector switch to either a, b, or a+b position for independent or simultaneous operation. 3. At the beginning of each shift prior to turning on the tr...

  • Page 53: 6.7 Changing Batteries

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 53 of 56 6.7 changing batteries change transmitter batteries (“aa” alkaline battery x 2) by unscrewing the battery cover located on the backside of the transmitter. During battery installation make sure the batteries are instal...

  • Page 54

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 54 of 56 6.9 system status light indications 6.9.1 transmitter status indications type display type indication 1 solid red voltage below 1.8v at initial power on or during operation 2 3 red blinks and then off voltage below 1.7...

  • Page 55

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 55 of 56 6.9.2 receiver status indications 6.9.3 receiver power indications 6.9.4 receiver com indications type display type (green & red) indication 1 fast green blinks decoding in process 2 slow green blinks decoding on stand...

  • Page 56: 7 General Specifications

    Flex 12ex2 standard, ab and tandem instruction manual november 2017 page 56 of 56 7 general specifications frequency range: 433.050mhz - 439.600mhz number of channels: 62 channels channel spacing: 50 khz modulation: digital frequency modulation based on manchester code, 20-bit address, 32-bit crc an...