Magnetek Flex EM User manual

Flex EM/EX Transmitter
Engineered
Remote Equipment Control
Part Number: 191-00424-0001 R0
February 2014
© 2014 Magnetek Material Handling

Your New Radio Remote
Thank you for your purchase of Magnetek’s Enrange®brand Flex Radio Remote Equipment Control.
Magnetek has set a whole new standard in radio-remote performance, dependability, and value with this
unique new line of handheld transmitters.
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:
+1.262.783.3500
Magnetek, Inc.
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
Canada Service Information:
4090B Sladeview Crescent
Mississauga, Ontario
L5L 5Y5 Canada
Phone: [phone]
Fax: [phone]
+1.416.424.7617 (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]
Fax: [phone]
©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. PRODUCT MANUAL SAFETY INFORMATION ................................................................................4
2. CRITICAL INSTALLATION CONSIDERATIONS............................................................................... 6
2.1 GENERAL ..................................................................................................................................... 6
2.2 PERSONS AUTHORIZED TO OPERATE RADIO CONTROLLED EQUIPMENT .......................6
2.3 SAFEY INFORMATION & RECOMMENDED TRAINING FOR OPERATORS............................7
2.4 PRE-OPERATION TEST .............................................................................................................. 8
2.5 TRANSMITTER UNIT ................................................................................................................... 8
2.6 BATTERIES .................................................................................................................................. 9
2.7 BATTERY HANDLING .................................................................................................................. 9
2.8 BATTERY CHARGING ................................................................................................................. 9
2.9 BATTERY DISPOSAL................................................................................................................... 9
3. GENERAL TRANSMITTER INFORMATION ................................................................................... 10
3.1 EXTERNAL ILLUSTRATION (12 Button CONFIGURATION) .................................................... 10
3.2 INTERNAL ILLUSTRATION (12 Button CONFIGURATION) ..................................................... 11
3.3 TYPES OF BUTTONS ................................................................................................................ 11
4. DIP-SWITCH SETTINGS................................................................................................................. 12
4.1 SYSTEM CHANNEL SETTINGS ................................................................................................12
4.2 INACTIVITY TIME-OUT TIMER.................................................................................................. 12
5. OPERATING PROCEDURE ............................................................................................................ 13
5.1 GENERAL OPERATING PROCEDURE.....................................................................................13
5.2 CHANGING TRANSMITTER BATTERIES .................................................................................14
5.3 STATUS LIGHTS INDICATORS & WARNINGS ........................................................................15
5.4 PUSH BUTTON ERROR TABLE ................................................................................................ 15
6. CHANNEL CONFIGURATION SETTINGS...................................................................................... 16
6.1 FCC STATEMENTS.................................................................................................................... 16
6.2 CHANNEL TABLE....................................................................................................................... 17
7. TROUBLESHOOTING ..................................................................................................................... 18
7.1 TROUBLESHOOTING TABLE.................................................................................................... 18
8. NOTES ............................................................................................................................................. 19

Enrange Flex EM/EX Instruction Manual
February 2014
Page 4 of 19
1. 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 radio control 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 devices controlled by radio controls:
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 EM/EX Instruction Manual
February 2014
Page 5 of 19
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 EM/EX Instruction Manual
February 2014
Page 6 of 19
2. 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.
2.1 GENERAL
Radio controlled material handling and mobile hydraulic equipment operates in several directions.
Cranes, hoists, lifting devices, other material handling and mobile hydraulic 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 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.
2.2 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, other material handling, and mobile hydraulic 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 EM/EX Instruction Manual
February 2014
Page 7 of 19
2.3 SAFEY 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 control system 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 radio control system 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 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
Change any settings or controls without authorization and proper training
Remove or obscure any warning or safety labels or tags

Enrange Flex EM/EX Instruction Manual
February 2014
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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.
2.4 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.
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 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.
This manual covers two types of Flex transmitters: the Flex EM and Flex EX. Refer to Section 3.3 for the
differences between these two transmitter types.

Enrange Flex EM/EX Instruction Manual
February 2014
Page 9 of 19
2.6 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.
2.7 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.
Keep the battery pack environment cool during charging operation and storage (i.e., not in direct sunlight
or close to a heating source).
2.8 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 circuit the charger.
Do not attempt to charge a damaged battery.
Use only Magnetek Enrange 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.
2.9 BATTERY DISPOSAL
Before disposing of batteries consult local and governmental regulatory requirements for proper disposal
procedure.

Enrange Flex EM/EX Instruction Manual
February 2014
Page 10 of 19
3. GENERAL TRANSMITTER INFORMATION
3.1 EXTERNAL ILLUSTRATION (12 BUTTON CONFIGURATION)
Figure 1 Figure 2
1. Emergency Stop Button
2. Removable Power Key
3. Push Button #1
4. Push Button #3
5. Push Button #5
6. Push Button #7
7. Push Button #9
8. Push Button #11
9. Push Button #2
10. Push Button #4
11. Push Button #6
12. Push Button #8
13. Push Button #10
14. Push Button #12
15. Strap Ring
16. System Information
17. System Channel
18. Unit Number
19. Battery Cover
20. FCC Information
NOTE: Push Buttons #9-#12 are not present on the Flex 8 EM or EX.
NOTE: Push Buttons #5-#12 are not present on the Flex 4 EM or EX.