1. DL manuals
  2. Magnetek
  3. Measuring Instruments
  4. Flex 12RS System
  5. Instruction Manual

Magnetek Flex 12RS System Instruction Manual

Manual is about: Radio Control Equipment

Summary of Flex 12RS System

  • Page 1

    Flex 8rs system radio control equipment instruction manual 0-flex-8rs-me r1 december 2012 © copyright 2012 magnetek material handling.

  • Page 2: Service Information

    Service information your new radio system thank you for your purchase of magnetek’s enrange™ flex ex radio remote control system. Without a doubt, our flex ex system is the ultimate solution for providing precise, undeterred, and safe control of your material. If your product ever needs modification...

  • Page 3

    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...

  • Page 4: Table of Contents

    Flex 8rs system instruction manual december 2012 1 of 36 table of contents 1. Introduction ............................................................................................................................................. 2 2. Radio controlled safety .........................................

  • Page 5: 1. Introduction

    Flex 8rs system instruction manual december 2012 2 of 36 1. Introduction the flex radio remote control systems are designed for control of industrial equipment and machinery such as overhead traveling cranes, jib cranes, gantry cranes, tower cranes, electric hoists, winches, monorails, conveyor belt...

  • Page 6: 2. Radio Controlled Safety

    Flex 8rs system instruction manual december 2012 3 of 36 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 ...

  • Page 7: Warning

    Flex 8rs system instruction manual december 2012 4 of 36 2.1 critical installation considerations warning prior to installation and operation of this equipment, read and develop an understanding of the contents of this manual and the operation manual of the equipment or device to which this equipmen...

  • Page 8

    Flex 8rs system instruction manual december 2012 5 of 36 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 controlle...

  • Page 9: Warning

    Flex 8rs system instruction manual december 2012 6 of 36 operate manual motions with other than manual power operate radio controlled equipment when low battery indicator is on warning the operator should not attempt to repair any radio controller. If any product performance or safety concerns are o...

  • Page 10: 2.8 Battery Handling

    Flex 8rs system instruction manual december 2012 7 of 36 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 ...

  • Page 11

    Flex 8rs system instruction manual december 2012 8 of 36 3. General system information 3.1 rs system description (8-rs types) type b: a/b receiver select with bridge receiver -8-button transmitter (bottom two buttons for a/b select) -3 receivers (a, b, and bridge) type c: a, b, c, d receiver select ...

  • Page 12: 3.2 Transmitter Handset

    Flex 8rs system instruction manual december 2012 9 of 36 3.2 transmitter handset 3.2.1 external illustration (8-button tx shown for reference) (fig. 01) (fig. 02) 1. Emergency stop button 9. Push button #5 2. Removable power key switch 10. Push button #7 3. Push button #2 11. Strap ring 4. Push butt...

  • Page 13

    Flex 8rs system instruction manual december 2012 10 of 36 3.2.2 internal illustration (fig. 03) (fig. 04) 1. Encoder board 6. I-chip 2. Aerial antenna 7. Function dip-switch 3. Transmitting module 8. Channel dip-switch 4. Status led display 9. Battery contact mechanism 5. Function led displays.

  • Page 14: 3.3 Receiver Unit

    Flex 8rs system instruction manual december 2012 11 of 36 7 6 1 2 3 4 5 3.3 receiver unit 3.3.1 external illustration (fig. 05) 1. External antenna jack 5. Com led display 2. Power led display 6. Output contact diagram 3. Status led display 7. Cord grip 4. Sq led display.

  • Page 15

    Flex 8rs system instruction manual december 2012 12 of 36 i-chip port 1 2 3 4 jp 7 jp 6 jp 5 jp 4 jp 3 jp 2 jp 1 system functions test 3.3.2 internal illustration (fig. 06) 1. Receiving module 3. Ac line filter board 2. Decoder + relay board 4. Power transformer.

  • Page 16: 4. Function Settings

    Flex 8rs system instruction manual december 2012 13 of 36 7 1 4 2 3 5 6 8 channel 7 1 4 2 3 5 6 8 4. Function settings 4.1 transmitter handset 4.1.1 system channel settings (fig. 07) set the transmitter channel by adjusting the channel dip-switch located on the backside of the transmitter encoder bo...

  • Page 17: Warning

    Flex 8rs system instruction manual december 2012 14 of 36 4.1.2 push button functions – setup warning the transmitters are unique and factory preset. Do not change the transmitter settings unless you are replacing an existing transmitter. Changing the settings could make it common with another trans...

  • Page 18

    Flex 8rs system instruction manual december 2012 15 of 36 4.1.2.2 type “c” transmitter setup and configuration push button rs system type c setting a,b,c,d receiver select on cts 1 2 3 4 5 6 7 8 function dip_sw type c a,b,c,d interlock/non-interlock transmitter s/n: xxxxxx type:01 a b c d b a d c a ...

  • Page 19

    Flex 8rs system instruction manual december 2012 16 of 36 push button rs system relay chart # 1 a-b-c-d select receiver relay logic relay k1 – button 1 1st speed relay k2 – button 2 1st speed relay k3 – button 1 2nd speed relay k4 – button 2 2nd speed relay k5 – button 3 1st speed relay k6 – button ...

  • Page 20

    Flex 8rs system instruction manual december 2012 17 of 36 4.1.3 channel change via push buttons other than channel dip-switch on the encoder board, the transmitter channel can also be changed directly on the push buttons. Please refer to the instruction below on how to change the transmitter channel...

  • Page 21

    Flex 8rs system instruction manual december 2012 18 of 36 4.1.4 optional 4-digit security code the 4-digit security code is an optional feature that can be programmed into the transmitter to allow operation only to those who know the code. If this feature is desired, set up as follows: prior to rota...

  • Page 22

    Flex 8rs system instruction manual december 2012 19 of 36 4.1.5 i-chip the i-chip functions in a way that is very similar to a sim card inside a mobile phone, which stores system information such as your telephone number, account number, phone book and other settings. The i-chip works exactly the sa...

  • Page 23: 4.2 Receiver Unit

    Flex 8rs system instruction manual december 2012 20 of 36 7 1 4 2 3 5 6 8 int ext 1 2 3 5 6 8 4 7 4.2 receiver unit 4.2.1 system channel settings (fig. 12) even though the flex system is equipped with an automatic channel scanning receiver, the user can also set the receiver channel manually. Please...

  • Page 24

    Flex 8rs system instruction manual december 2012 21 of 36 4 1 3 2 6 5 8 7 4 1 3 2 6 5 8 7 4 2 3 1 7 8 5 6 4 1 2 3 6 5 7 8 4.2.2 receiver auto-scanning settings receiver channel dip-switch ↓ (1) → scanning all 62 channels (manufacture preset) for standard operation (2) → single fixed channel auto sca...

  • Page 25

    Flex 8rs system instruction manual december 2012 22 of 36 8 7 6 5 4 3 2 1 1 2 3 456 7 8 1 234 56 7 8 rel ay f unc tions relay functions system functions test jp 7 jp 6 jp 5 jp 4 jp 3 jp 2 jp 1 i-chip port pb1 & pb 2 pb 3 & pb4 pb5 & pb6 4.2.3 dip-switch settings 0000001 (switches 1 through 6 off, sw...

  • Page 26

    Flex 8rs system instruction manual december 2012 23 of 36 system functions test jp 7 jp 6 jp 5 jp 4 jp 3 jp 2 jp 1 i-chip port jp 1 jp 2 jp 3 jp 4 jp 5 jp 6 jp 7 test system functions 4.2.4 jumper settings note: all settings are pre-set at the factory; information to be used for replacement receiver...

  • Page 27

    Flex 8rs system instruction manual december 2012 24 of 36 4.2.4.1 setup tables for 8-rs system types: flex rs system – type b a/ b, trolley/hoist receiver select with bridge receiver with 8 button transmitter receiver settings i-chip type jumper jp4 jumper jp5 t/h receiver a 01 open open t/h receive...

  • Page 28

    Flex 8rs system instruction manual december 2012 25 of 36 system functions test jp 7 jp 6 jp 5 jp 4 jp 3 jp 2 jp 1 i-chip port i-chip port 4.2.5 i-chip programming port (fig. 17) the i-chip programming port located on the decoder module (refer to fig. 17 above) inside the receiver is designed for th...

  • Page 29: 5. System Channels Table

    Flex 8rs system instruction manual december 2012 26 of 36 5. System channels table channel frequency dip-switch setting channel frequency dip-switch setting 01 433.000mhz 000000 32 433.775mhz 100000 01 433.000mhz 000001 33 433.800mhz 100001 02 433.025mhz 000010 34 433.825mhz 100010 03 433.050mhz 000...

  • Page 30: 6. Receiver Installation

    Flex 8rs system instruction manual december 2012 27 of 36 6. Receiver installation 6.1 output relay contact diagram * for 12 - 24vdc power supply, wire #1 corresponds to the negative charge (-) and wire #3 corresponds to the positive charge (+). Wire #2 is for ground. * wire #6 is for “normal close”...

  • Page 31: 6.3

    Flex 8rs system instruction manual december 2012 28 of 36 6.2 pre-installation precautions 1. Make sure the transmitter and receiver have identical serial number/id codes and channels. 2. Make sure the receiver is not set to the same channel as any other systems in use in the surrounding area. 3. Ma...

  • Page 32: 6.4 System Testing

    Flex 8rs system instruction manual december 2012 29 of 36 8 3. Ensure the selected location has adequate space to accommodate the receiver (refer to fig. 18 on page 28). 4. For better reception, make sure the receiver is in an upright position. 5. Drill one hole (8mm in diameter) on the control pane...

  • Page 33: 7. Operating Procedure

    Flex 8rs system instruction manual december 2012 30 of 36 7. Operating procedure 7.1 transmitter operation 7.1.1 general operating procedure a. Reset the red emergency stop button located on the top left hand side of the transmitter handset by rotating it either clockwise or counter clockwise. The r...

  • Page 34

    Flex 8rs system instruction manual december 2012 31 of 36 type b type c f. In case of an emergency, pressing down on the red emergency stop button will immediately disconnect the receiver mainline (status led blinks red). To reset the emergency stop button just rotate the red button either clockwise...

  • Page 35

    Flex 8rs system instruction manual december 2012 32 of 36 1 2 7.1.2 automatic channel scanning operating procedure after changing the transmitter channel (refer to page 13), turn on the transmitter power and rotate the power key switch to “start” position and hold it there for up to 1 minute. Within...

  • Page 36

    Flex 8rs system instruction manual december 2012 33 of 36 7.2 status light indicators & warnings 7.2.1 transmitter status light indication type display type indication 1 constant red voltage goes below 1.9v at initial power on - transmitter power shuts off. Voltage goes below 1.8v during operation -...

  • Page 37

    Flex 8rs system instruction manual december 2012 34 of 36 7.2.2 receiver status light indication type display type indication 1 fast green blinks decoding in process 2 slow green blinks decoding on standby 3 slow red blinks stop command initiated with receiver main deactivated 4 two red blinks recei...

  • Page 38: 7.3 Trouble Shooting Tips

    Flex 8rs system instruction manual december 2012 35 of 36 7.3 trouble shooting tips problems possible reasons suggestions no response when transmitter push button is pressed (improper startup & settings) transmitter low battery power check the transmitter battery level. Emergency stop button activat...

  • Page 39: 8. System Specifications

    Flex 8rs system instruction manual december 2012 36 of 36 8. System specifications frequency range : 433 ~ 434 mhz frequency deviation : 12.5 khz number of channels : 62 channels modulation : digital frequency modulation based on manchester code, 20bit address, 32bit crc parity check and hamming cod...