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Magnetek FLEX-6EX Instruction Manual

Other manuals for FLEX-6EX: Instruction Manual
Manual is about: Radio control equipment

Summary of FLEX-6EX

  • Page 1

    Flex 6ex system radio control equipment instruction manual 0-flex-6ex-me r3 march 2016 © copyright 2016 magnetek material handling.

  • Page 2: Service Information

    Flex 6ex system instruction manual march 2016 page 1 of 38 service information your new radio system thank you for your purchase of magnetek’s 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...

  • Page 3

    Flex 6ex system instruction manual march 2016 page 2 of 38 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 manu...

  • Page 4: Table of Contents

    Flex 6ex system instruction manual march 2016 page 3 of 38 table of contents 1. Introduction ........................................................................................................................................ 5 2. Radio controlled safety ............................................

  • Page 5

    Flex 6ex system instruction manual march 2016 page 4 of 38 7.2.1 transmitter status light indication ........................................................................................... 35 7.2.2 receiver status light indication ....................................................................

  • Page 6: 1. Introduction

    Flex 6ex system instruction manual march 2016 page 5 of 38 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 be...

  • Page 7: 2. Radio Controlled Safety

    Flex 6ex system instruction manual march 2016 page 6 of 38 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 a...

  • Page 8: Warning

    Flex 6ex system instruction manual march 2016 page 7 of 38 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 equipm...

  • Page 9: Warning

    Flex 6ex system instruction manual march 2016 page 8 of 38 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 control...

  • Page 10: 2.5 Transmitter Unit

    Flex 6ex system instruction manual march 2016 page 9 of 38 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 ...

  • Page 11: 2.9 Battery Disposal

    Flex 6ex system instruction manual march 2016 page 10 of 38 2.9 battery disposal before disposing of batteries consult local and governmental regulatory requirements for proper disposal procedure. 2.10 crane/lifting device specific warnings warning all equipment must have a mainline contactor instal...

  • Page 12: 3.1 Transmitter Handset

    Flex 6ex system instruction manual march 2016 page 11 of 38 3. General systems information 3.1 transmitter handset 3.1.1 external illustration (fig. 01) (fig. 02) 1. Emergency stop button 8. Push button #5 2. Removable power key switch 9. Strap ring 3. Push button #2 10. System information 4. Push b...

  • Page 13

    Flex 6ex system instruction manual march 2016 page 12 of 38 3.1.2 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: 3.2 Receiver Unit

    Flex 6ex system instruction manual march 2016 page 13 of 38 3.2 receiver unit 3.2.1 external illustration (fig. 05) 1. External antenna jack (optional) 4. Sq led display 2. Power led display 5. Com led display 3. Status led display 6. Output contact diagram 7. Cord grip.

  • Page 15

    Flex 6ex system instruction manual march 2016 page 14 of 38 3.2.2 internal illustration (fig. 06) 1. Receiving module 3. Ac line filter/relay board 2. Decoder/relay board 4. Power transformer.

  • Page 16: 4. Function Settings

    Flex 6ex system instruction manual march 2016 page 15 of 38 7 1 4 2 3 5 6 8 channel 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 board (refer to ...

  • Page 17

    Flex 6ex system instruction manual march 2016 page 16 of 38 4.1.2 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 instructions below on how to change the transmitter chan...

  • Page 18

    Flex 6ex system instruction manual march 2016 page 17 of 38 4.1.3 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 ro...

  • Page 19

    Flex 6ex system instruction manual march 2016 page 18 of 38 4.1.4 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. I-chip works exactly the same...

  • Page 20: 4.2 Receiver Unit

    Flex 6ex system instruction manual march 2016 page 19 of 38 int ext 1 2 3 5 6 8 4 7 4.2 receiver unit 4.2.1 system channel settings (fig. 10) even though the flex system is equipped with an automatic channel scanning mode, the user can also set the receiver channel manually. Please refer to page 33 ...

  • Page 21

    Flex 6ex system instruction manual march 2016 page 20 of 38 f1 r1 f/r2 f1 f2 r1 r2 4.2.2 output relay configurations 4.2.2.1 output relay types a. Three (3) output relays per motion – shared 2 nd speed output relay output relays with forward 1 st speed (f1), reverse 1 st speed (r1) and forward/rever...

  • Page 22

    Flex 6ex system instruction manual march 2016 page 21 of 38 b. 4-output relays configuration with opened/closed contact at 2 nd speed at 2 nd speed, only the 2 nd speed (f2 or r2) output relay is closed (refer to page 23 on how to set to this function). C. 4-output relays configuration with closed/c...

  • Page 23

    Flex 6ex system instruction manual march 2016 page 22 of 38 aux stop 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 4.2.2.6 auxiliary stop push button function the auxiliary stop function acts as a 2 nd emergency stop button. Other than by emergency stop button and transmitter power...

  • Page 24

    Flex 6ex system instruction manual march 2016 page 23 of 38 1 3 2 4 7 5 6 8 8 7 6 5 4 3 2 1 1 234 5 67 8 1 234 5 67 8 re lay fu ncti on s relay functions system functions test jp 7 jp 6 jp 5 jp 4 jp 3 jp 2 jp 1 i-chip port pb 1 & pb 2 pb3 & p b4 pb5 & pb6 4.2.4 dip-switch settings 4.2.4.1 interlocke...

  • Page 25

    Flex 6ex system instruction manual march 2016 page 24 of 38 4.2.4.2 non-interlocked functions contrary to interlocked settings, non-interlocked settings allow the two adjacent push buttons be used simultaneously. Non-interlocked settings are usually applied to a crane’s auxiliary functions, such as ...

  • Page 26

    Flex 6ex system instruction manual march 2016 page 25 of 38 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 4.2.5 jumper settings jumper settings are applied to functions such as main-disconnect time, start function, syste...

  • Page 27

    Flex 6ex system instruction manual march 2016 page 26 of 38 system functions test jp 7 jp 6 jp 5 jp 4 jp 3 jp 2 jp 1 i-chip port i-chip port 4.2.6 i-chip programming port (fig. 15) the i-chip programming port, located on the decoder module (refer to fig. 15 above) inside the receiver, is designed fo...

  • Page 28: 5. System Channels Table

    Flex 6ex system instruction manual march 2016 page 27 of 38 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 0...

  • Page 29: 6. Recevier Installation

    Flex 6ex system instruction manual march 2016 page 28 of 38 6. Recevier installation 6.1 output relay contact diagram * for 3-relay (shared 2 nd speed) and 4-relay (separate 2 nd speed) configurations please refer to page 20. * for 4-relay closed/closed and 4-relay opened/closed relay configurations...

  • Page 30

    Flex 6ex system instruction manual march 2016 page 29 of 38 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. ...

  • Page 31

    Flex 6ex system instruction manual march 2016 page 30 of 38 8 1. For best reception the location of the receiver should be visible to the operator at all time. 2. The location selected should not be exposed to high levels of electric noise. Mounting the receiver next to an unshielded variable freque...

  • Page 32: 6.4 System Testing

    Flex 6ex system instruction manual march 2016 page 31 of 38 6.4 system testing 1. Turn on the power source to the receiver and test the main relay output by pressing the red emergency stop button and observe that it properly opens and closes the mainline disconnect contactor. 2. Test the operation o...

  • Page 33: 7. Operating Procedure

    Flex 6ex system instruction manual march 2016 page 32 of 38 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...

  • Page 34

    Flex 6ex system instruction manual march 2016 page 33 of 38 e. In case of an emergency, pressing down the red emergency stop button will immediately disconnect the receiver main and as well as the transmitter power. To resume operation, rotate the red button clockwise or counter clockwise, and it wi...

  • Page 35

    Flex 6ex system instruction manual march 2016 page 34 of 38 7.1.3 changing transmitter batteries change the transmitter batteries by unscrewing the battery cover located on the backside of the transmitter (refer to fig. 17 below). During battery installation make sure that the blue ribbon is centere...

  • Page 36

    Flex 6ex system instruction manual march 2016 page 35 of 38 7.2 status light indicators & warnings 7.2.1 transmitter status light indication type display type indication 1 constant red voltage below 1.9v at initial power on - transmitter power and receiver main shuts off. Voltage below 1.8v during o...

  • Page 37

    Flex 6ex system instruction manual march 2016 page 36 of 38 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 two red blinks receiver main jammed or defective 4 fast red blinks incorrect transmitter s...

  • Page 38: 7.3 Trouble Shooting Tips

    Flex 6ex system instruction manual march 2016 page 37 of 38 7.3 trouble shooting tips problems possible reasons suggestions no response when transmitter push button is pressed (improper startup & settings) transmitter has low battery power check the transmitter battery level. Emergency stop button a...

  • Page 39: 8. System Specifications

    Flex 6ex system instruction manual march 2016 page 38 of 38 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 c...