Magnetek FLEX M Series User manual

FLEX M
Pre-Engineered
(Flex M-16, -24, -32)
Modular Receiver
Part Number: 198-00121 R4
October 2014
© 2014 Magnetek Material Handling

Your New Radio Receiver
Thank you for your purchase of Magnetek’s Enrange®brand 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)
Magnetek Material Handling
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
Telephone: [phone]
Website: www.magnetek.com
E-mail: [e-mail]
Fax Numbers:
Main: +1.800.298.3503
Sales: +1.262.783.3510
Service: +1.262.783.3508
Magnetek, Inc. has additional satellite locations for Canada and the United States. For more
information, please visit http://www.magnetek.com.
©2014 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.

TABLE OF CONTENTS
1.0: CRITICAL INSTALLATION CONSIDERATIONS..................................................................... 3
1.1 GENERAL.............................................................................................................................. 3
1.2 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED EQUIPMENT................ 3
1.3 SAFETY INFORMATION & RECOMMENDED TRAINING FOR OPERATORS .................. 4
1.4 PRE-OPERATION TEST....................................................................................................... 5
2.0 FLEX M RECEIVER INSTALLATION ....................................................................................... 6
2.1 PRE-INSTALLATION............................................................................................................. 6
2.2 MECHANICAL DRAWINGS................................................................................................... 7
2.3 INSTALLATION ..................................................................................................................... 8
2.4 REMOVAL.............................................................................................................................. 9
3.0 NORMAL OPERATION........................................................................................................... 10
3.1 POWER SUPPLY MODULE................................................................................................ 10
3.2 RF/CPU MODULE............................................................................................................... 10
3.3 RELAY MODULE(S)............................................................................................................ 10
4.0 FLEX MODULE TYPES .......................................................................................................... 11
4.1 FLEX RF/CPU MODULE..................................................................................................... 11
4.1.1Bank 1 Dip Switch Setting Definitions ....................................................................... 11
4.1.1.1Bank 1 Switches 1 through 5 – Relay configuration program select................. 11
4.1.1.2Bank 1 Switch 6 – Invert A/B Select Outputs (Normally OFF) .......................... 11
4.1.1.3Bank 1 Switch 7 – Auxiliary Relay Output Select (Normally OFF).................... 12
4.1.1.4Bank 1 Switch 8 – Disable Tandem (A/B both) Select (Normally OFF)............ 12
4.1.2Bank 2 Dip Switch Setting Definitions ....................................................................... 12
4.1.2.1Bank 2 Switch 1 – AUX 1/2 Output Configuration (Normally ON)..................... 12
4.1.2.2Bank 2 Switch 2 – AUX 3/4 Output Configuration (Normally ON)..................... 12
4.1.2.3Bank 2 Switch 3 – AUX 5/6 Output Configuration (Normally ON)..................... 13
4.1.2.4Bank 2 Switches 4 thru 8 – Radio Frequency channel select........................... 13
4.2 FLEX M RELAY MODULE................................................................................................... 13
4.3 FLEX M 120VAC POWER MODULE .................................................................................. 14
5.0 FLEX SYSTEMS – OVERVIEW, SETTINGS AND WIRING DIAGRAMS .............................. 16
5.1 FLEX M-16 SYSTEM OVERVIEW ...................................................................................... 16
5.1.1 Flex M 16 Relay Configuration Settings (Bank 1 on RF/CPU Module)......................... 16
5.1.2 Flex M 16 Relay Configuration Descriptions................................................................. 17
5.2 FLEX M-24 SYSTEM OVERVIEW ...................................................................................... 21
5.2.1 Flex M 24 Relay Configuration Settings (Bank 1 on RF/CPU Module)......................... 21
5.2.2 Flex M 24 Relay Configuration Descriptions................................................................. 22
5.3 FLEX M-32 SYSTEM OVERVIEW ...................................................................................... 23
5.3.1 Flex M 32 Relay Configuration Settings (Bank 1 on RF/CPU Module)......................... 23
5.3.2 Flex M 32 Relay Configuration Descriptions................................................................. 24
6.0 CHANNEL CONFIGURATION SETTINGS (BANK 2 ON RF/CPU MODULE)....................... 27
6.1 FCC STATEMENTS ............................................................................................................ 27
7.0 TROUBLESHOOTING ............................................................................................................ 28
7.1 TROUBLESHOOTING TABLE ............................................................................................ 29
7.2 ASSEMBLY AND REPLACEMENT PARTS........................................................................ 31

Enrange Flex M Pre-Engineered Modular Receiver Manual
October 2014
Page 1 of 31
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 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 our 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 and lifting devices:
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 overhead material handling industry.
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 owner of the Magnetek Products 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.
WARRANTY INFORMATION
FOR INFORMATION ON MAGNETEK’S PRODUCT WARRANTIES BY PRODUCT TYPE, PLEASE VISIT
WWW.MAGNETEK.COM.

Enrange Flex M Pre-Engineered Modular Receiver Manual
October 2014
Page 2 of 31
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.

Enrange Flex M Pre-Engineered Modular Receiver Manual
October 2014
Page 3 of 31
1.0: 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
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, 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.
1.1 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.
1.2 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED EQUIPMENT
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.

Enrange Flex M Pre-Engineered Modular Receiver Manual
October 2014
Page 4 of 31
1.3 SAFETY INFORMATION & RECOMMENDED TRAINING FOR 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 receiver 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 receiver when not in use
be trained in transferring a radio control receiver to another person
be trained how and when to report unsafe or unusual operating conditions
test the receiver 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

Enrange Flex M Pre-Engineered Modular Receiver Manual
October 2014
Page 5 of 31
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
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.
1.4 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 receiver emergency stop.

Enrange Flex M Pre-Engineered Modular Receiver Manual
October 2014
Page 6 of 31
2.0 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.
2.1 PRE-INSTALLATION
1. The transmitter and receiver access code and channel must match before the system will
communicate.
2. Be aware of other radio channels in the surrounding area - set your system to a unique channel.
3. Make sure that your equipment is working properly in manual mode prior to system installation.
4. Make sure the power to the receiver is the correct voltage.
5. Disconnect equipment power prior to system installation.

Enrange Flex M Pre-Engineered Modular Receiver Manual
October 2014
Page 7 of 31
2.2 MECHANICAL DRAWINGS
TYPICAL MECHANICAL LAYOUTS
Figure 1: Mechanical Layout