Magnetek Flex Pro Series User manual

Flex Pro Tethered
Controller
Remote Control Equipment
Instruction Manual
198-00132 R05
April 2019
© Copyright 2019 Magnetek

Flex Pro Tethered Controller Instruction Manual
April 2019
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SERVICE INFORMATION
Your New Remote Control System
Thank you for your purchase of Magnetek’s Flex Pro Tethered Controller. Without a doubt, our Flex Pro
systems are 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)
International Service
262-783-3500
World Headquarters:
Magnetek, Inc.
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
Telephone: [phone]
Website: www.magnetek.com
E-mail: [e-mail]
Fax Numbers:
Main: 800-298-3503
Sales: 262-783-3510
Service: 262-783-3508
Canada Service Information:
161 Orenda Road
Unit 1
Brampton, Ontario
L6W 1W3 Canada
Phone: [phone]
Fax: [phone]
416-424-7617 (24/7 Service pager)
EU Market Contact:
Brian Preston
Magnetek (UK) Ltd.
Unit 3 Bedford Business Centre
Mile Road
Bedford, MK42 9TW UK
Phone: [phone]
©2019 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.

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Table of Contents
1PREFACE AND SAFETY ......................................................................................................................4
1.1 PRODUCT SAFETY INFORMATION ...........................................................................................4
2INTRODUCTION...................................................................................................................................5
3REMOTE CONTROLLED SAFETY ......................................................................................................6
3.1 GENERAL.....................................................................................................................................7
3.2 PERSONS AUTHORIZED TO OPERATE REMOTE CONTROLLED CRANES..........................7
3.3 SAFETY INFORMATION AND RECOMMENDED TRAINING FOR REMOTE CONTROLLED
EQUIPMENT OPERATORS.....................................................................................................................8
3.4 CONTROLLER UNIT ....................................................................................................................9
3.5 PRE-OPERATION TEST...............................................................................................................9
3.6 SPECIFIC SYSTEM WARNINGS.................................................................................................9
4GENERAL CONTROLLER INFORMATION....................................................................................... 10
4.1 EXTERNAL ILLUSTRATION (Pro 12 Configuration)..................................................................10
4.2 INTERNAL ILLUSTRATION (Pro 12 Configuration) ...................................................................11
4.3 TYPES OF BUTTONS ................................................................................................................12
4.4 ADJUSTABLE SPEED CONTROL .............................................................................................12
5DIP SWITCH SETTINGS ................................................................................................................... 13
5.1 INACTIVITY TIME-OUT TIMER..................................................................................................13
6SETUP................................................................................................................................................ 14
6.1 INSTALLATION OF TETHERED CONTROLLER CABLE..........................................................14
6.2 UNIT POWER .............................................................................................................................14
6.3 CAN CONNECTOR PINOUT......................................................................................................15
6.4 J9139 PROTOCOL .....................................................................................................................16
6.5 CANOpen PROTOCOL...............................................................................................................18
7OPERATING PROCEDURE............................................................................................................... 21
7.1 GENERAL OPERATING PROCEDURE.....................................................................................21
7.2 STATUS LIGHT INDICATORS AND WARNINGS.......................................................................22
7.3 PUSH BUTTON ERROR TABLE ................................................................................................23
7.4 TROUBLESHOOTING TIPS.......................................................................................................23
8DECLARATION OF CONFORMITY................................................................................................... 24

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1 PREFACE AND SAFETY
1.1 PRODUCT 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 SafetyAdministration (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.MAGNETEK.COM.

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2 INTRODUCTION
The Flex remote control systems are designed for control of industrial equipment and mobile machinery
such as overhead traveling cranes, construction equipment, forestry equipment, mining equipment, rail
equipment, drilling and trenching equipment, agriculture equipment, electric hoists, winches, monorails,
conveyor belts, mining equipment and other material handling equipment where hardwired remote control is
preferred.
List of notable features include:
•Over one million unique ID codes (20bit) – Each and every Flex system has its own unique ID
code; no repeats.
•Advanced controls – The Flex system utilizes advanced microprocessor controls with 16-bit
CRC which provides 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 are rated for more than one
million press cycles.
•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 European Directives (Safety, EMC,
R&TTE, and Machinery) and Industry Canada Specifications (IC).

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3 REMOTE 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
Remote Control System.

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WARNING
PRIOR TO INSTALLATION AND OPERATION OF THIS EQUIPMENT, READ AND DEVELOPAN UNDERSTANDING
OF THE CONTENTS OF THIS MANUALAND 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.
FOLLOW YOUR LOCAL LOCKOUT TAGOUT PROCEDURE BEFORE MAINTAINING ANY REMOTE
CONTROLLED EQUIPMENT. ALWAYS REMOVE ALL ELECTRICAL POWER FROM THE 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.
AFTER INSTALLATION BE SURE TO VERIFY THAT THE TRANSMITTER IS NOT INTERFERING WITH OTHER
EQUIPMENT IN THE AREA. ALSO VERIFY THAT OTHER EQUIPMENT IS NOT INTERFERING WITH THE
TRANSMITTER AND ITS ASSOCIATED EQUIPMENT. FAILURE TO FOLLOW THESE WARNINGS COULD
RESULT IN SERIOUS INJURY OR DEATH AND DAMAGE TO EQUIPMENT.
3.1 GENERAL
Radio controlled equipment operates in several directions. Quite frequently, the equipment is operated in areas where
people are working in close proximity to the 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.
3.2 PERSONS AUTHORIZED TO OPERATE REMOTE CONTROLLED
CRANES
Only properly trained persons designated by management should be permitted to operate radio controlled equipment.
Radio controlled 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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3.3 SAFETY INFORMATION AND RECOMMENDED TRAINING FOR
REMOTE CONTROLLED EQUIPMENT OPERATORS
Anyone being trained to operate remote controlled equipment should possess as a minimum the following knowledge
and skills before using the remote 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 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 equipment that utilizes the radio
control
•know how to keep the operator and other people clear of hazardous areas
•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:
•operate the equipment if the direction of travel or function engaged does not agree with what is indicated on
the controller
•operate any damaged or malfunctioning equipment
•change any settings or controls without authorization and proper training
•remove or obscure any warning or safety labels or tags
•leave power on the radio controlled equipment when the equipment is not in operation
•operate any 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

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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.
3.4 CONTROLLER UNIT
Controller switches should never be mechanically blocked ON or OFF. When not in use, the operator should turn the
controller OFF. A secure storage space should be provided for the controller unit, and the controller unit should
always be placed there when not in use. This precaution will help prevent unauthorized people from operating the
material handling equipment.
Spare controllers should be stored in a secure storage space and only removed from the storage space after the
current controller in use has been turned OFF, taken out of the service area and secured.
3.5 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 controller emergency stop.
3.6 SPECIFIC SYSTEM WARNINGS
Below are some specific operating safety tips that should be strictly followed when operating a Flex Pro system:
1. Check the Status LED on the controller for any signs of irregularities (refer to page 22).

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4 GENERAL CONTROLLER INFORMATION
4.1 EXTERNAL ILLUSTRATION (Pro 12 Configuration)
Figure 1
Figure 2
E. Emergency Stop Button 6. Push Button #6 SC. Strap Ring
S. Removable Power Key Switch 7. Push Button #7 SN. System Information
1. Push Button #1 8. Push Button #8 CC. CAN Connector
2. Push Button #2 9. Push Button #9 MN. Crane Number
3. Push Button #3 10. Push Button #10
4. Push Button #4 11. Push Button #11
5. Push Button #5 12. Push Button #12
NOTE: Push buttons #9 through #12 are not present on the Flex Pro 8 Module.

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4.2 INTERNAL ILLUSTRATION (Pro 12 Configuration)
Figure 3
Figure 4
1. Encoder Board 5. I-CHIP
2. CAN Module 6. Dip Switch
3. Status LED Display 7. CAN Connector
4. Function LED Displays
NOTE: The Flex Pro 8 Module will differ slightly.

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4.3 TYPES OF BUTTONS
The buttons used on the Flex Pro tethered controller are fully proportional, stepless push buttons
with an output that varies 0-100% (based on how far the button is depressed). It is possible to
model the stepless buttons as an On/Off momentary switch, On/Off latched switch, 2 Speed button,
or a 3 Speed button. This modeling is done on the receiver end of the system. Please consult the
factory for more information.
4.4 ADJUSTABLE SPEED CONTROL
The proportional buttons normally operate on a scale from 0-100%, but can also be scaled down to
operate linearly from 0-75%, 0-50%, or 0-25% over the full motion of the button. This gives the user
more control over lower speeds. To adjust the speed control settings, press and hold the Start
button, then press push button 1 or push button 2 to decrement/increment the range percentage.
The red LEDs, which indicate the Speed Setting, will then change to reflect the current setting.
Figure 5
Figure 6
Start +
Speed control setting
PB1 Decrement Speed Control
PB2 Increment Speed Control

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5 DIP SWITCH SETTINGS
Figure 7
5.1 INACTIVITY TIME-OUT TIMER
Bits 6 and 7 on the dip switch allows the user to define a time after which, if no buttons on
the controller are pressed, the Flex Pro tethered controller will send an OFF command to
the equipment and power down. To restart, the user must turn the On/Off/Start switch to
the Off position, then back to On again to resume operation.
Figure 8
Time Out
Dip
switch
Setting
5 minutes 01
10 minutes 10
15 minutes 11
Never shut off 00

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6 SETUP
6.1 INSTALLATION OF TETHERED CONTROLLER CABLE
The tethered controller cable is attached to the CAN connector on the controller by lining up the alignment
groove and inserting the plug into the CAN connector receptacle. Twist the locking ring on the CAN plug
clockwise to tighten it down and prevent accidental disengagement.
6.2 UNIT POWER
Section 6.3 shows the connections to provide power to the unit. The Flex Pro tethered controller has an
input voltage range of 7.0 - 36VDC. For applications that operate at voltages above 36VDC, a voltage
regulator will need to be installed to regulate the voltage to a value that is accepted by the Flex Pro
tethered controller.
When connecting the Flex Pro tethered controller to a Magnetek receiver, the receiver does not provide
power to the tethered controller. As such, the tethered controller will need to be wired to another power
source. Typically Magnetek will provide a cable with flying leads that is used to wire the tethered
controller to the receiver. The power and ground portions of this cable will need to be connected to an
external power source for the tethered controller to properly operate.

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6.3 CAN CONNECTOR PINOUT

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6.4 J9139 PROTOCOL
The standard J1939 messages that the Flex Pro tethered controller transmits are shown below. For
custom messaging, consult the factory.

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6.5 CANOpen PROTOCOL
The standard CANOpen messages that the Flex Pro tethered controller transmits are shown below. For
custom messaging, consult the factory.
Transmit PDO 1
CANopen 8bit Digital Inputs (1-8)
Magnetek Device Transmit
CAN ID Node Id + 0x180
Transmission Repetition Rate 50ms
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
CANopen 8bit Digital Input 1 Byte 1 000 0 3210
CANopen 8bit Digital Input 2 Byte 2 76543210
CANopen 8bit Digital Input 3 Byte 3 76543210
CANopen 8bit Digital Input 4 Byte 4 76543210
CANopen 8bit Digital Input 5 Byte 5 76543210
CANopen 8bit Digital Input 6 Byte 6 76543210
CANopen 8bit Digital Input 7 Byte 7 76543210
CANopen 8bit Digital Input 8 Byte 8 76543210
Values:
Power Down Reason 4 bits
Reserved
1 bit
Start/MLC (momentary) 1 bit
Commands Valid (see notes) 1 bit
Stop Output (On for operational state) 1 bit
(not used) 8 individual digital bits
(not used) 8 individual digital bits
(not used) 8 individual digital bits
(not used) 8 individual digital bits
(not used) 8 individual digital bits
(not used) 8 individual digital bits
LED 100, 75, 50 25 8 individual digital bits

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Transmit PDO 2
CANopen 16bit signed analog Inputs (1-4)
Magnetek Device Transmit
CAN ID Node Id + 0x181
Transmission Repetition Rate 50ms
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Byte 1 76543210
Byte 2 15 14 13 12 11 10 98
Byte 3 76 5 43210
Byte 4 15 14 13 12 11 10 98
Byte 5 76543210
Byte 6 15 14 13 12 11 10 98
Byte 7 76 5 43210
Byte 8 15 14 13 12 11 10 98
CANopen 16bit Analog Input 3
CANopen 16bit Analog Input 4
CANopen 16bit Analog Input 2
CANopen 16bit Analog Input 1
Values:
Button1 0-250
Button2 0-250
Button3 0-250
Button4 0-250
Transmit PDO 3
CANopen 16bit signed analog Inputs (5-8)
Magnetek Device Transmit
CAN ID Node Id + 0x182
Transmission Repetition Rate 50ms
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Byte 1 76 5 432 1 0
Byte 2 15 14 13 12 11 10 9 8
Byte 3 7 6 5 4 3210
Byte 4 15 14 13 12 11 10 98
Byte 5 7654321 0
Byte 6 15 14 13 12 11 10 9 8
Byte 7 7654 3 210
Byte 8 15 14 13 12 11 10 98
CANopen 16bit Analog Input 5
CANopen 16bit Analog Input 6
CANopen 16bit Analog Input 7
CANopen 16bit Analog Input 8
Values:
Button5 0-250
Button6 0-250
Button7 0-250
Button8 0-250

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Transmit PDO 4
CANopen 16bit signed analog Inputs (9-12)
Magnetek Device Transmit
CAN ID Node Id + 0x183
Transmission Repetition Rate 50ms
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Byte 1 76543210
Byte 2 15 14 13 12 11 10 98
Byte 3 76543210
Byte 4 15 14 13 12 11 10 98
Byte 5 76 5 43210
Byte 6 15 14 13 12 11 10 98
Byte 7 76543210
Byte 8 15 14 13 12 11 10 98
CANopen 16bit Analog Input 12
CANopen 16bit Analog Input 9
CANopen 16bit Analog Input 10
CANopen 16bit Analog Input 11
Values:
Button9 0-250
Button10 0-250
Button11 0-250
Button12 0-250
Configure Heartbeat Timer - SDO Download 1017sub0
Set heartbeat message timer in mS
Magnetek Device Receive
CAN ID Node Id + 0x600
Transmission Repetition Rate single shot
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
SDO Download Command Byte 1
Byte 2
Byte 3
CANopen Object SubIndex
Byte 4
Byte 5
Byte 6
Byte 7
Byte 8
0x22
CANopen Object Index
0x1017 (Producer Heartbeat Time)
0x00 (Producer Heartbeat Time)
CANopen Object Value
Value for heartbeat message time in milliseconds