Magnetek Flex 8EX A/B User manual

Flex 8EX-A/B System
Radio Control Equipment
Instruction Manual
0-FLEX-8EXABME-R1
June 2010
© Copyright 2010 Magnetek Material Handling

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 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)
Magnetek Material Handling
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
Telephone: [phone]
Website: www.magnetekmh.com
E-mail: [email protected]
Fax Numbers:
Main: 1.800.298.3503
Sales: 1.262.783.3510
Service: 1.262.783.3508
Canada Service Information:
4090B Sladeview Crescent
Mississauga, Ontario
L5L 5Y5 Canada
Telephone: [phone]
Fax: [phone]

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Table of Contents
Page
1. Introduction 4
2. Radio Controlled Safety 5
3. General System Information
A. Transmitter Handset
1. External Illustration (Standard Push Button Configuration) 11
2. Internal Illustration 12
B. Receiver Unit
1. External Illustration 13
2. Internal Illustration 14
4. Function Settings
A. Transmitter Handset
System Channel Settings 15
1. Push Button Functions with LED Displays
a. Standard Push Button Configuration (Transmitter Toggle) 16
b. Standard Push Button Configuration (A/B Selector) 17
c. Inline Push Button Configuration (Transmitter Toggle) 18
d. Inline Push Button Configuration (A/B Selector) 19
2. Channel Change via Push Buttons 20
3. Program 4-Digit Security Code 21
4.I-CHIP 22
B. Receiver Unit
1. System Channel Settings 23
2. Output Relay Configurations
a. Output Relay Types 24
b. Output Relay Action at 2nd Speed 24-25
c. ON/OFF Push Button Function 25
d. START/AUX Function 26
e. Magnet ON/OFF Push Button Function 26
f. Brake Function 26
g. Momentary Contact 26
h. Toggled Contact 26
i. 3rd Speed Push Button Function 26
j. Auxiliary STOP Push Button Function 27
k. Pitch & Catch Function 27

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3. Receiver Auto-Scanning Settings 27
4. Dip-Switch Settings
a. Interlocked Functions 28
b. Non-Interlocked Functions 29
5. Jumper Settings 30
6. I-CHIP Programming Port 31
7. Voltage Settings 31
5. System Channels Table 32
6. Receiver Installation
A. Output Relay Contact Diagram 33
B. Pre-Installation Precautions 34
C. Step-by-Step Installation 34-35
D. SystemTesting 35
7. Operating Procedure
A. Transmitter Operation
1. General Operating Procedure 36-37
2. Rotary Select A/B Operating Procedure 37
3. Push Button Select A/B Operating Procedure 37
4. 3rd Speed Push Button Operating Procedure 37
5. Pitch & Catch Operating Procedure 38
6. Automatic Channel Scanning Operating Procedure 38
7. Changing Transmitter Batteries 38
B. Status Light Indicators & Warnings
1. Transmitter Status Light Indication 39
2. Receiver Status Light Indication 40
3. Receiver SQ Light Indication 40
4. Receiver POWER Light Indication 40
5. Receiver COM Light Indication 40
C. Trouble Shooting Tips 41
8. System Specifications 42

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PRODUCT MANUAL SAFETY INFORMATION
Magnetek, Inc. (Magnetek) offers a broad range of radio remote control products, control products
and adjustable frequency drives, and industrial braking systems for material handling applications. This
manual has been prepared by Magnetek to provide information and recommendations for the installation,
use, operation and service of Magnetek’s material handling products and systems (Magnetek Products).
Anyone who uses, operates, maintains, services, installs or owns Magnetek Products should know,
understand and follow the instructions and safety recommendations in this manual for Magnetek
Products.
The recommendations in this manual do not take precedence over any of the following
requirements relating to cranes, hoists lifting devices or other material handling equipment which use or
include Magnetek Products:
Instructions, manuals, and safety warnings of the manufacturers of the equipment where the
radio system is used,
Plant safety rules and procedures of the employers and the owners of facilities where the
Magnetek Products are being used,
Regulations issued by the Occupational Health and Safety Administration (OSHA),
Applicable local, state or federal codes, ordinances, standards and requirements, or
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.

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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 belts, mining equipment and other material handling equipment where wireless control is
preferred.
Each Flex system consists of a transmitter handset and receiver unit. Other standard-equipped accessories
include 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:
* 62 user-programmable channels – Advanced synthesized RF controls with 62 built-in channels;
there are no more fixed channels and fragile quartz crystals to break.
* Automatic channel scanning receiver – No more hassle of climbing up the crane to change
receiver channels.
* Over one million unique ID codes (20bit) – Each and every Flex system has its own unique ID
codes and serial number; never repeats.
* Advanced controls – The Flex system utilizes advanced microprocessor controls with 32bit CRC
and Hamming Code, which provide ultra fast, safe, precise, and error-free encoding and decoding.
* Unique I-CHIP design – The I-CHIP functions in a way that is very similar to SIM cards used on
mobile phones, with the ability to transfer system information and settings from one transmitter to
another without the hassle of resetting the spares.
* Reliable push buttons – The in-house designed push buttons with gold-plated contacts are rated for
more than one million press cycles.
* Low power consumption – Requires only two “AA” Alkaline batteries for more than 100 hours of
operating time between replacements.
* Ultra-durable nylon and fiberglass composite enclosures – Highly resistant to breakage and
deformation even in the most abusive environments.
* Full compliance – All systems are fully compliant with the FCC Part-15 Rules, European Directives
(Safety, EMC, R&TTE, Machinery), and Industry Canada Specifications (IC).

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2. Radio Controlled Safety
WARNINGS and CAUTIONS
Throughout this document WARNING and CAUTION statements have been deliberately placed to highlight items
critical to the protection of personnel and equipment.
WARNING – A warning highlights an essential operating or maintenance procedure, practice, etc. which if
not strictly observed, could result in injury or death of personnel, or long term physical hazards. Warnings
are highlighted as shown below:
WARNING
CAUTION – A caution highlights an essential operating or maintenance procedure, practice, etc. which if not
strictly observed, could result in damage to, or destruction of equipment, or loss of functional effectiveness.
Cautions are highlighted as shown below:
CAUTION
WARNINGS and CAUTIONS SHOULD NEVER BE DISREGARDED.
The safety rules in this section are not intended to replace any rules or regulations of any applicable local, state, or
federal governing organizations. Always follow your local lockout and tagout procedure when maintaining any radio
equipment. The following information is intended to be used in conjunction with other rules or regulations already in
existence. It is important to read all of the safety information contained in this section before installing or operating the
Radio Control System.

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1.1: 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 EQUIPMENT WILL BE INTERFACED. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN
SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
ALL EQUIPMENT MUST HAVE A MAINLINE CONTACTOR INSTALLED AND ALL TRACKED CRANES, HOISTS,
LIFTING DEVICES AND SIMILAR EQUIPMENT MUST HAVE A BRAKE INSTALLED. FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
AN AUDIBLE AND/OR VISUAL WARNING MEANS MUST BE PROVIDED ON ALL REMOTE CONTROLLED
EQUIPMENT AS REQUIRED BY CODE, REGULATION, OR INDUSTRY STANDARD. THESE AUDIBLE AND/OR
VISUAL WARNING DEVICES MUST MEET ALL GOVERNMENTAL REQUIREMENTS. FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
FOLLOW YOUR LOCAL LOCKOUT TAGOUT PROCEDURE BEFORE MAINTAINING ANY REMOTE
CONTROLLED EQUIPMENT. ALWAYS REMOVE ALL ELECTRICAL POWER FROM THE CRANE, HOIST, LIFTING
DEVICE OR SIMILAR EQUIPMENT BEFORE ATTEMPTING ANY INSTALLATION PROCEUDRES. DE-ENERGIZE
AND TAGOUT ALL SOURCES OF ELECTRICAL POWER BEFORE TOUCH-TESTING ANY EQUIPMENT. FAILURE
TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
THE DIRECT OUTPUTS OF THIS PRODUCT ARE NOT DESIGNED TO INTERFACE DIRECTLY TO TWO STATE
SAFETY CRITICAL MAINTAINED FUNCTIONS, I.E., MAGNETS, VACUUM LIFTS, PUMPS, EMERGENCY
EQUIPMENT, ETC. A MECHANICALLY LOCKING INTERMEDIATE RELAY SYSTEM WITH SEPARATE POWER
CONSIDERATIONS MUST BE PROVIDED. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS
INJURY OR DEATH OR DAMAGE TO EQUIPMENT.
1.2: GENERAL
Radio controlled material handling equipment operates in several directions. Cranes, hoists, lifting devices and other
material handling equipment can be large, and operate at high speeds. Quite frequently, the equipment is operated
in areas where people are working in close proximity to the material handling equipment. The operator must
exercise extreme caution at all times. Workers must constantly be alert to avoid accidents. The following
recommendations have been included to indicate how careful and thoughtful actions may prevent injuries, damage to
equipment, or even save a life.
1.3: PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED CRANES
Only properly trained persons designated by management should be permitted to operate radio controlled equipment.
Radio controlled cranes, hoists, lifting devices and other material handling equipment should not be operated by any
person who cannot read or understand signs, notices and operating instructions that pertain to the equipment.
Radio controlled equipment should not be operated by any person with insufficient eyesight or hearing or by any
person who may be suffering from a disorder or illness, is taking any medication that may cause loss of equipment
control, or is under the influence of alcohol or drugs.

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1.4: SAFETY INFORMATION AND RECOMMENDED TRAINING FOR RADIO CONTROLLED
EQUIPMENT OPERATORS
Anyone being trained to operate radio controlled equipment should possess as a minimum the following knowledge
and skills before using the radio controlled equipment.
The operator should:
have knowledge of hazards pertaining to equipment operation
have knowledge of safety rules for radio controlled equipment
have the ability to judge distance of moving objects
know how to properly test prior to operation
be trained in the safe operation of the radio transmitter as it pertains to the crane, hoist, lifting device or other
material handling equipment being operated
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
be trained in transferring a radio control transmitter to another person
be trained how and when to report unsafe or unusual operating conditions
test the transmitter emergency stop and all warning devices prior to operation; testing should be done on each
shift, without a load
be thoroughly trained and knowledgeable in proper and safe operation of the crane, hoist, lifting device, or
other material handling equipment that utilizes the radio control
know how to keep the operator and other people clear of lifted loads and to avoid “pinch” points
continuously watch and monitor status of lifted loads
know and follow cable and hook inspection procedures
know and follow the local lockout and tagout procedures when servicing radio controlled equipment
know and follow all applicable operating and maintenance manuals, safety procedures, regulatory
requirements, and industry standards and codes
The operator shall not:
lift or move more than the rated load
operate the material handling equipment if the direction of travel or function engaged does not agree with
what is indicated on the controller
use the crane, hoist or lifting device to lift, support or transport people
lift or carry any loads over people
operate the crane, hoist or lifting device unless all persons, including the operator, are and remain clear of
the supported load and any potential pinch points
operate a crane, hoist or lifting device when the device is not centered over the load
operate a crane, hoist or lifting device if the chain or wire rope is not seated properly in the sprockets, drum
or sheave
operate any damaged or malfunctioning crane, hoist, lifting device or other material handling equipment

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change any settings or controls without authorization and proper training
remove or obscure any warning or safety labels or tags
leave any load unattended while lifted
leave power on the radio controlled equipment when the equipment is not in operation
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 is on
WARNING
THE OPERATOR SHOULD NOT ATTEMPT TO REPAIR ANY RADIO CONTROLLER. IF ANY PRODUCT
PERFORMANCE OR SAFETY CONCERNS ARE OBSERVED, THE EQUIPMENT SHOULD IMMEDIATELY BE
TAKEN OUT OF SERVICE AND BE REPORTED TO THE SUPERVISOR. DAMAGED AND INOPERABLE RADIO
CONTROLLER EQUIPMENT SHOULD BE RETURNED TO MAGNETEK FOR EVALUATION AND REPAIR.
FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO
EQUIPMENT.
1.5: TRANSMITTER UNIT
Transmitter switches should never be mechanically blocked ON or OFF. When not in use, the operator should turn
the transmitter OFF. A secure storage space should be provided for the transmitter unit, and the transmitter unit
should always be placed there when not in use. This precaution will help prevent unauthorized people from operating
the material handling equipment.
Spare transmitters should be stored in a secure storage space and only removed from the storage space after the
current transmitter in use has been turned OFF, taken out of the service area and secured.
1.6: PRE-OPERATION TEST
At the start of each work shift, or when a new operator takes control of the crane, operators should do, as a
minimum, the following steps before making lifts with any crane or hoist:
Test all warning devices.
Test all direction and speed controls.
Test the transmitter emergency stop.

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1.7: BATTERIES
WARNING
KNOW AND FOLLOW PROPER BATTERY HANDLING, CHARGING AND DISPOSAL PROCEDURES. IMPROPER
BATTERY PROCEDURES CAN CAUSE BATTERIES TO EXPLODE OR DO OTHER SERIOUS DAMAGE.
FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO
EQUIPMENT.
1.8: BATTERY HANDLING
Use only batteries approved by Magnetek for the specific product.
Do not dispose of a battery pack in fire; it may explode.
Do not attempt to open the battery pack.
Do not short circuit the battery.
For intrinsically safe environments only use specified Magnetek Telemotive intrinsically safe batteries.
Keep the battery pack environment cool during charging operation and storage (i.e., not in direct sunlight or close to a
heating source).
1.9: BATTERY CHARGING
For those transmitters equipped with battery chargers, please familiarize all users with the instructions of the charger
before attempting to use.
Do not attempt to charge non-rechargeable battery packs.
Avoid charging partially discharged rechargeable batteries to help prolong battery cycle life.
Avoid charging the battery pack for more than 24 hours at a time.
Do not charge batteries in a hazardous environment.
Do not short the charger.
Do not attempt to charge a damaged battery.
Use only Magnetek Telemotive approved chargers for the appropriate battery pack.
Do not attempt to use a battery that is leaking, swollen or corroded.
Charger units are not intended for outdoor use. Use only indoors.
1.10: BATTERY DISPOSAL
Before disposing of batteries consult local and governmental regulatory requirements for proper disposal procedure.

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1.11: SPECIFIC SYSTEM WARNINGS
Below are some specific operating safety tips that should be strictly followed when operating a Flex 8EX-
A/B System:
1. Check the Status LED on the transmitter for any signs of low battery power (refer to page 39).
2. Check the Status LED on the transmitter for any signs of irregularities (refer to page 39).
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 a crane or equipment with two transmitter handsets at the same time unless
they are programmed with “Pitch & Catch” function. For information on the “Pitch & Catch”
feature, please refer to page 27 and page 38 of this manual.

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3. General System Information
A. TRANSMITTER HANDSET
1. External Illustration (Standard Push Button
Configuration)
(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 Button #4 12. System Information
5. Push Button #6 13. System Channel
6. Select A, B, A+B Rotary Switch 14. Crane Number
7. Push Button #1 15. Battery Cover
8. Push Button #3 16. FCC Information

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2. Internal Illustration
(Fig. 03) (Fig. 04)
1. Encoder Board 6. I-CHIP
2. Arial Antenna 7. Function Dip-Switch
3. Transmitting Module 8. Channel Dip-Switch
4. Status LED Display 9. Battery Contact Mechanism
5. Function LED Displays

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B. RECEIVER UNIT
1. External Illustration
(Fig. 05)
1. Shock Mount 6. COM LED Display
2. External Antenna Jack 7. Output Contact Diagram
3. Power LED Display 8. System Information
4. Status LED Display 9. Cord Grip
5. SQ LED Display

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2. Internal Illustration
(Fig. 06)
1. AC Line Filter 4. Decoder Module
2. Power Transformer 5. Output Relay Board
3. Receiving Module

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71423 56 8
CHANNEL
71 423 56 8
4. Function Settings
A. TRANSMITTER HANDSET
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 Fig. 07 above). Only the first six (6) positions are used for
channel programming (refer to Fig. 08 below). The system channels table located on page32
illustrates which dip-switch setting corresponds to which channel. Once the transmitter channel
is altered, make sure to change the receiver channel as well. The channel on both the
transmitter and receiver must be identical in order for the system to work. To change the
receiver channel please refer to page 23.
Example: Top slot →“1”
Bottom slot →“0”
(Fig. 08)
The above dip-switch setting “1 0 0 1 0 0” corresponds to “channel 36” in the system channels
table on page 32.

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52134 867
FUNCTION
LED 1LED 2LED 3LED 4
2. Push Button Functions with LED Displays
A. Standard Push Button Configuration (Transmitter Toggle)
Set the transmitter toggle (latching output relay) function by adjusting the 8-position
function dip-switch located on the backside of the transmitter encoder board (refer to Fig.
09 below). The LED 1 through LED 4 shown inside the shaded box (see below) illustrates
which LED on the transmitter will light up when the designated push button (PB5 - PB7)
is pressed.
(Fig. 09)
DIP PB5 PB6 PB7
1 00000000 Normal Normal Normal
2 00000101 Normal Normal Normal
3 00000110 Normal Normal LED 3
4 00000111 Normal LED 2 LED 3
5 00001000 LED 1 LED 2 LED 3
* PB5…PB7 →Push button number
* Normal →Normal momentary contact
* LED 1…LED 4 →Transmitter toggled with designated LED Display

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B. Standard Push Button Configuration (A/B Selector)
There are four (4) different types of A/B selector sequences available on the Flex
system. Choose the one that is most suitable for your application.
Type-A selector sequence : A+B →A →B →A+B …
Type-B selector sequence : Off →A →B →Off →A →B …
Type-C selector sequence : A →B →A+B →A →B →A+B …
Type-D selector sequence : Off →A →B →A+B →Off →A →B →A+B …
DIP PB5 PB6 PB7
6 00101111 Normal Normal A/1&2
7 00110000 Normal Normal B/1&2
8 00110001 Normal Normal C/1&2
9 00110010 Normal Normal D/1&2
10 00110011 Normal Normal Normal
11 00110100 Normal Normal Normal
12 00110101 Normal Normal Normal
13 00110110 Normal Normal Normal
14 00110111 Normal Normal A/1&2
15 00111000 Normal Normal A/1&2
16 00111001 Normal Normal A/1&2
17 00111010 Normal Normal A/1&2
18 00111011 Normal Normal B/1&2
19 00111100 Normal Normal B/1&2
20 00111101 Normal Normal B/1&2
21 00111110 Normal Normal C/1&2
22 00111111 Normal Normal C/1&2
23 01000000 Normal Normal D/1&2
* PB5…PB7 →Push button number
* Normal →Normal momentary contact
* A/1&2…D/3&4 →A/B Selector type with designated LED Display (LED 1&2 or LED 3&4)

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C. Inline Push Button Configuration (Transmitter Toggle)
The push button arrangement for inline push button setup starts from top to bottom and
then from the right column to the left column (refer to Fig. 10 below). To set the inline
push button configuration, please refer to JP4 and JP5 jumpers setting on page 30. With
inline push button configurations, PB1 & PB2 still corresponds to output relay K1~K4,
PB3 & PB4 corresponds to relay K5~K8, etc…
(Fig. 10)
DIP PB5 PB6 PB7
24 00000000 Normal Normal Normal
25 00000101 Normal Normal Normal
26 00010100 Normal Normal LED 3
27 00010101 Normal LED 2 LED 3
28 00010110 LED 1 LED 2 LED 3
* PB5…PB7 →Push button number
* Normal →Normal momentary contact
* LED 1…LED 4 →Transmitter toggled with designated LED Display