Magnetek Flex I-Chip User manual

Flex I-Chip
Remote Crane Controls
August 2010
Part Number: 198-50014
© 2010 Magnetek Material Handling

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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: 800.298.3503
Sales: 262.783.3510
Service: 262.783.3508
Canada Service Information:
4090B Sladeview Crescent
Mississauga, Ontario
L5L 5Y5 Canada
Phone: [phone]
Fax: [phone]
©2009 MAGNETEK MATERIAL HANDLING
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.

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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 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.MAGNETEKMH.COM.

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Table of Contents
A. Exterior Illustrations...................................................................................................................................... 5
B. Testing Complete Transmitter ...................................................................................................................... 6
C. Testing Encoder Board.................................................................................................................................. 7
D. Testing Receiving Module............................................................................................................................. 9
E. Decoder Module Programming .................................................................................................................. 10
F. I-Chip programming......................................................................................................................................11
1. LCD and keypad illustrations...................................................................................................................11
2. Copy I-Chip.................................................................................................................................................11
3. Program System Serial Number.............................................................................................................. 12
4. Program System Type.............................................................................................................................. 12
5. Program Start/Aux Function.................................................................................................................... 12
6. Program Transmitter Output Power ....................................................................................................... 13
7. Program Transmitter On Time / Transmitting Time............................................................................... 13
8. Program System RF Channel.................................................................................................................. 13
9. Program Transmitter Push Button Functions ....................................................................................... 13
Table A-1. Transmitter Toggle with LED Displays................................................................................... 14
Table A-2. Inline Transmitter Toggle with LED Displays ........................................................................ 14
Table B-1. A/B Push Button Select........................................................................................................... 16
Table B-2. Inline A/B Push Button Select................................................................................................. 19
Table C-1. Combination of Transmitter Toggle + A/B Push Button Select........................................... 23
Table C-2. Combination of Transmitter Toggle + A/B Push Button Select........................................... 26
10. BRAKE Function (not required if programmed directly on the decoder module - Section E) ......... 27
11. PASSWORD / Security Code Function................................................................................................... 27

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A. Exterior Illustrations
1) Fuse(1.0A) 8) Power cable to encoder board
2) Power LED 9) Cable to encoder board’s CN1 connector
3) SQ1 LED (internal receiving module) 10) Cable to I-Chip slot on decoder modules
4) I-Chip LED 11) Test mode select button
5) SQ2 LED (external receiving module) 12) External receiving module input slot
6) I-Chip slot 13) External power input slot (not provided)
7) Internal battery compartment 14)Powerswitch

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B. Testing Complete Transmitter
To check if the transmitter handset is in good order please follow the instruction below.
1) Press the Test Mode Select button until the LCD screen displays “Testing Complete Transmitter 1”.
2) The LCD screen is displayed as follows:
Testing Complete Transmitter
S - - - - - - T - - M - - CH 01
↓↓↓↓
Serial number Type Mode Channel
3) First set this unit’s channel identical to the one set on the transmitter handset to be tested via the ↑& ↓
push buttons on the keypad.
4) Turn on the transmitter and rotate the power key to Start position.
5) At this time the SQ1 LED should blink red with the transmitter information displayed on the LCD screen.
If SQ1 LED does blink red but does not have the transmitter information shown on the LCD screen then
the encoder board is defective. If nothing is shown at all (both SQ1 LED and transmitter information),
then either the internal transmitting board or the encoder board is defective. If this is the case, then
proceed to section C to check the transmitting board and encoder board.
6) If SQ1 LED does blink red with the transmitter information shown on the LCD screen then go on to
check all the push button commands.
7) Press all the push buttons on the transmitter, one at a time, to check if this unit decodes all the
pushbutton commands. When a push button is pressed, an arrow should appear below the system
information, for both 1st and 2nd steps. If not, then the encoder board is defective. If only one or two push
buttons do not display the arrows on the LCD screen when pressed, then those push buttons are
defective.
8) If all the information is correct then the transmitter handset is in good order. Go on to section D to

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+
-
check the receiving module.
C. Testing Encoder Board
To check if the encoder boards is in good order please follow the instructions below.
1) Press the Test Mode Select button until the LCD screen displays “Testing Encoder Board 5”.
2) The LCD screen is displayed as follows:
Testing Encoder Board
S - - - - - - T - - M - -
↓↓↓
Serial number Type Mode
3) Plug all the required cables onto this unit
4) Plug all the cables from this unit to the encoder board.

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5) Make sure the encoder board has an I-Chip installed.
6) Press and hold on to the power switch.
7) Press the Start micro switch one time and let go. The LED 1 should blink green.
8) At this time the LCD screen should display the transmitter I-Chip information. If not, then the encoder
board is defective.
9) If the LCD screen does display transmitter information correctly, then press all the push buttons on the
encoder board one at a time to see if the unit decodes all the pushbutton commands. When a push
button is pressed, an arrow should appear below the system information displays, for both 1st and 2nd
steps. If not, then the encoder board is defective. If only one or two push buttons do not display the
arrows on the LCD screen when pressed, then those push buttons are defective.
10) If all the information is correct then the encoder board is in good order. If this is the case, then the
transmitting board is defective.

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D. Testing Receiving Module
To check if the receiving module is in good order please follow the instructions below.
1) Press the Test Mode Select button until the LCD screen displays “Testing Receiver Module 2”.
2) The LCD screen is displayed as follows:
Testing Receiving Module
S - - - - - - T - - M - -
↓↓↓
Serial number Type Mode
3) Plug the receiving module to be tested on to this unit.
4) Use a good transmitter handset (any type) to test the receiving module.
5) Set the channel dip switch on the receiving module to the one set on the transmitter.
6) Turn the transmitter power on and rotate the power key to the Start position. The SQ2 LED should light
up or blink; if not, then the receiving module is defective.
7) If SQ2 LED blinks red with all the transmitter information shown on the LCD screen then the decoder
module is defective.

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E. Decoder Module Programming
You can program the serial number, system type, Start/Aux, brake function and service date onto the decoder
module.
1) Plug all the required cables onto this unit.
2) Plug the cable from this unit to the I-Chip slot on the decoder module.
3) Press the Test Mode Select button until the LCD screen displays “Decoder Programming 4”.
4) Set the serial number, system type, Start/Aux and brake function by using Next, Previous, ↑& ↓arrows
and keypad. Press Copy button when done.

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Previous
012
CDEF
B
A
3
456
789
Next
Read
Copy
--
-------
TIMER CH FUNCPWR
AUXTYPE
S/ N
-- -- ----
-- --
5) Scroll down to the next screen by pressing the Next button. The production and service date
information will appear. Only the service date can be reprogrammed.
F. I-Chip programming
Press the Test Mode Select button until the LCD screen displays “I-Chip Programming 3”.
1. LCD and keypad illustrations
2. Copy I-Chip
If you do not have an empty I-Chip on hand, you can store the original I-Chip’s information into the
programmer unit temporarily and perform a copy at later time.
Steps: First insert the original I-Chip onto the I-Chip slot, press READ button to store original I-Chip
information into the programmer unit (red light will appear on the I-Chip LED then green again), insert an
empty I-Chip onto the same I-Chip slot, press the COPY button to transfer information from the
programmer unit to the empty I-Chip (red light will appear on the I-Chip LED, then turn green again). This
will complete the programming.

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3. Program System Serial Number
Change the system’s serial number simply by moving the black arrow on the LCD screen to the S/N
location via NEXT and PREVIOUS button, then either press the ↑& ↓arrows or the number buttons
directly to change the serial number.
When finished, take the same I-Chip and insert it onto the I-Chip programming port (located on the
decoder module) to transfer the serial number from the I-Chip to the receiver. To transfer I-Chip information
to the receiver, JP6 must be inserted (not required if programmed directly on the decoder module –
Section E).
4. Program System Type
Change the system type simply by moving the black arrow on the LCD screen to the TYPE location via NEXT
and PREVIOUS button, then press the ↑& ↓arrows to change value. For standard systems, always set the
value at “00”. For tandem transmitters, you must set tandem transmitter-Ato “01” value and tandem
transmitter-B to “02” value.
When finished, take the same I-Chip and insert it onto the I-Chip programming port (located on the
decoder module) to transfer the Tandem function to the receiver (transmitter-Ato receiver-Aand
transmitter-B to receiver-B). To transfer I-Chip information to the receiver, JP6 must be inserted (not
required if programmed directly on the decoder module – Section E).
5. Program Start/Aux Function
(not required if programmed directly on the decoder module - Section E)
After initiating the START function, the same location will then become anAUX function. You can set the
FUNCTION relay in the receiver, when rotate to START position, the relay will close momentarily, toggled or
toggled affected by E-Stop activation. When set with the START/AUX function, the external warning function
is no longer available.Add the START/AUX function simply by moving the black arrow on the LCD screen to
the AUX location via NEXT and PREVIOUS button, and then press the ↑& ↓arrows to change value.
--- : START function only, no AUX function thereafter.
NOR : START function + AUX with normal momentary contact.
TOG : START function + AUX with toggled/latching contact.
T/E : START function + AUX with toggled/latching contact affected by the E-Stop
button (FUNCTION relay will open when e-stop button is pressed down)
EXT : FUNCTION relay works simultaneously with receiver MAIN.
When finished, take the same I-Chip and insert it onto the I-Chip programming port (located on the

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decoder module) to transfer the START/AUX function to the receiver. To transfer I-Chip information
to the receiver, JP6 must be inserted (not required if programmed directly on the decoder
module – Section E).
6. Program Transmitter Output Power
Change transmitter output power simply by moving the black arrow on the LCD screen to the PWR
location via NEXT and PREVIOUS button, then press ↑& ↓arrows to change the output power.
“-23” value will give you the shortest transmitting range but longest battery life while “+12” value will
give you the longest transmitting range but shortest battery life. We recommend that for indoor
applications, the transmitter output power should be set from “-5” to “+3” value. For outdoor
applications, we recommend that you set the transmitter output power from “+6” to “+10” value.
7. Program Transmitter On Time / Transmitting Time
Not applicable for FCC systems.
8. Program System RF Channel
Change the system channel simply by moving the black arrow on the LCD screen to the CH
location via NEXT and PREVIOUS button, then either press the ↑& ↓arrows or the number buttons
directly to change system channel.
9. Program Transmitter Push Button Functions
Program transmitter push button functions (transmitter toggle and select functions) simply by
moving the black arrow on the LCD screen to the FUNC location via NEXT and PREVIOUS button,
then either press the ↑& ↓arrows or the number buttons directly to set transmitter push button
functions. The transmitter push button function tables on the following pages tell you which number
value correspond to which push button function.

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Table A-1. Transmitter Toggle with LED Displays
No Dip-switch
Setting
PB1 PB2 PB3 PB4 PB5 PB6 PB7 PB8 PB9 PB10 PB11 PB12
1 00000001 4
2 00000010 3 4
3 00000011 2 3 4
4 00000100 1 2 3 4
5 00000101 4
6 00000110 3 4
7 00000111 2 3 4
8 00001000 1 2 3 4
9 00001001 4
10 00001010 3 4
11 00001011 2 3 4
12 00001100 1 2 3 4
13 00001101 4
14 00001110 3 4
15 00001111 2 3 4
16 00010000 1 2 3 4
Table A-2. Inline Transmitter Toggle with LED Displays
No Dip-switch
Setting
PB1 PB2 PB3 PB4 PB5 PB6 PB7 PB8 PB9 PB10 PB11 PB12
1 00000001 4
17 00010001 3 4
18 00010010 2 3 4
19 00010011 1 2 3 4
5 00000101 4
20 00010100 3 4
21 00010101 2 3 4
22 00010110 1 2 3 4
5 00000101 4
20 00010100 3 4
21 00010101 2 3 4

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Table A-2. Inline Transmitter Toggle with LED Displays
No Dip-switch
Setting
PB1 PB2 PB3 PB4 PB5 PB6 PB7 PB8 PB9 PB10 PB11 PB12
22 00010110 1 2 3 4
9 00001001 4
23 00010111 3 4
24 00011000 2 3 4
25 00011001 1 2 3 4
13 00001101 4
26 00011010 3 4
27 00011011 2 3 4
28 00011100 1 2 3 4

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Table B-1. A/B Push Button Select
Select Type A: A, B, A, B…
Magnetek/Enrange Select Type A: A+B, A, B, A+B…
Select Type B: Off, A, B, Off…
Select Type C: A, B, A+B, A…
Select Type D: Off, A, B, A+B, Off…
No Dip-switch
Setting
PB1 PB2 PB3 PB4 PB5 PB6 PB7 PB8 PB9 PB10 PB11 PB12
29 00011101 A/1.2
30 00011110 B/1.2
31 00011111 C/1.2
32 00100000 D/1.2
33 00100001 A/3.4
34 00100010 B/3.4
35 00100011 C/3.4
36 00100100 D/3.4
37 00100101 A/1.2 A/3.4
38 00100110 A/1.2 B/3.4
39 00100111 A/1.2 C/3.4
40 00101000 A/1.2 D/3.4
41 00101001 B/1.2 B/3.4
42 00101010 B/1.2 C/3.4
43 00101011 B/1.2 D/3.4
44 00101100 C/1.2 C/3.4
45 00101101 C/1.2 D/3.4
46 00101110 D/1.2 D/3.4
47 00101111 A/1.2
48 00110000 B/1.2
49 00110001 C/1.2
50 00110010 D/1.2
51 00110011 A/3.4
52 00110100 B/3.4
53 00110101 C/3.4
54 00110110 D/3.4

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Table B-1. A/B Push Button Select
Select Type A: A, B, A, B…
Magnetek/Enrange Select Type A: A+B, A, B, A+B…
Select Type B: Off, A, B, Off…
Select Type C: A, B, A+B, A…
Select Type D: Off, A, B, A+B, Off…
No Dip-switch
Setting
PB1 PB2 PB3 PB4 PB5 PB6 PB7 PB8 PB9 PB10 PB11 PB12
55 00110111 A/1.2 A/3.4
56 00111000 A/1.2 B/3.4
57 00111001 A/1.2 C/3.4
58 00111010 A/1.2 D/3.4
59 00111011 B/1.2 B/3.4
60 00111100 B/1.2 C/3.4
61 00111101 B/1.2 D/3.4
62 00111110 C/1.2 C/3.4
63 00111111 C/1.2 D/3.4
64 01000000 D/1.2 D/3.4
65 01000001 A/1.2
66 01000010 B/1.2
67 01000011 C/1.2
68 01000100 D/1.2
69 01000101 A/3.4
70 01000110 B/3.4
71 01000111 C/3.4
72 01000111 D/3.4
73 01001001 A/1.2 A/3.4
74 01001010 A/1.2 B/3.4
75 01001011 A/1.2 C/3.4
76 01001100 A/1.2 D/3.4
77 01001101 B/1.2 B/3.4
78 01001110 B/1.2 C/3.4
79 01001111 B/1.2 D/3.4
80 01010000 C/1.2 C/3.4
81 01010001 C/1.2 D/3.4

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Table B-1. A/B Push Button Select
Select Type A: A, B, A, B…
Magnetek/Enrange Select Type A: A+B, A, B, A+B…
Select Type B: Off, A, B, Off…
Select Type C: A, B, A+B, A…
Select Type D: Off, A, B, A+B, Off…
No Dip-switch
Setting
PB1 PB2 PB3 PB4 PB5 PB6 PB7 PB8 PB9 PB10 PB11 PB12
82 01010010 D/1.2 D/3.4
83 01010011 A/1.2
84 01010100 B/1.2
85 01010101 C/1.2
86 01010110 D/1.2
87 01010111 A/3.4
88 01011000 B/3.4
89 01011001 C/3.4
90 01011010 D/3.4
91 01011011 A/1.2 A/3.4
92 01011100 A/1.2 B/3.4
93 01011101 A/1.2 C/3.4
94 01011110 A/1.2 D/3.4
95 01011111 B/1.2 B/3.4
96 01100000 B/1.2 C/3.4
97 01100001 B/1.2 D/3.4
98 01100010 C/1.2 C/3.4
99 01100011 C/1.2 D/3.4
100 01100100 D/1.2 D/3.4

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Table B-2. Inline A/B Push Button Select
Select Type A: A, B, A, B…
Magnetek/Enrange Select Type A: A+B, A, B, A+B…
Select Type B: Off, A, B, Off…
Select Type C: A, B, A+B, A…
Select Type D: Off, A, B, A+B, Off…
No Dip-switch
Setting
PB1 PB2 PB3 PB4 PB5 PB6 PB7 PB8 PB9 PB10 PB11 PB12
101 01100101 A/1.2
102 01100110 B/1.2
103 01100111 C/1.2
104 01101000 D/1.2
33 00100001 A/3.4
34 00100010 B/3.4
35 00100011 C/3.4
36 00100100 D/3.4
105 01101001 A/1.2 A/3.4
106 01101010 A/1.2 B/3.4
107 01101011 A/1.2 C/3.4
108 01101100 A/1.2 D/3.4
109 01101101 B/1.2 B/3.4
110 01101110 B/1.2 C/3.4
111 01101111 B/1.2 D/3.4
112 01110000 C/1.2 C/3.4
113 01110001 C/1.2 D/3.4
114 01110010 D/1.2 D/3.4
115 01110011 A/1.2
116 01110100 B/1.2
117 01110101 C/1.2
118 01110110 D/1.2
51 00110011 A/3.4
52 00110100 B/3.4
53 00110101 C/3.4
54 00110110 D/3.4

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Table B-2. Inline A/B Push Button Select
Select Type A: A, B, A, B…
Magnetek/Enrange Select Type A: A+B, A, B, A+B…
Select Type B: Off, A, B, Off…
Select Type C: A, B, A+B, A…
Select Type D: Off, A, B, A+B, Off…
No Dip-switch
Setting
PB1 PB2 PB3 PB4 PB5 PB6 PB7 PB8 PB9 PB10 PB11 PB12
119 01110111 A/1.2 A/3.4
120 01111000 A/1.2 B/3.4
121 01111001 A/1.2 C/3.4
122 01111010 A/1.2 D/3.4
123 01111011 B/1.2 B/3.4
124 01111100 B/1.2 C/3.4
125 01111101 B/1.2 D/3.4
126 01111110 C/1.2 C/3.4
127 01111111 C/1.2 D/3.4
128 10000000 D/1.2 D/3.4
115 01110011 A/1.2
116 01110100 B/1.2
117 01110101 C/1.2
118 01110110 D/1.2
51 00110011 A/3.4
52 00110100 B/3.4
53 00110101 C/3.4
54 00110110 D/3.4
119 01110111 A/1.2 A/3.4
120 01111000 A/1.2 B/3.4
121 01111001 A/1.2 C/3.4
122 01111010 A/1.2 D/3.4
123 01111011 B/1.2 B/3.4
124 01111100 B/1.2 C/3.4
125 01111101 B/1.2 D/3.4
126 01111110 C/1.2 C/3.4
127 01111111 C/1.2 D/3.4